Chevrolet - Malibu - Workshop Manual - 2010 - 2010 (2)

Page 1117 Alignment: Service and Repair Front Camber Adjustment Front Camber Adjustment 1. Reach around the tire, using the appropriate extension and socket. 2. Loosen both strut to knuckle nuts just enough to allow for movement. A/C - Front/Rear Passenger Carpet Wet Housing Assembly HVAC: Customer Interest A/C - Front/Rear Passenger Carpet Wet TECHNICAL Bulletin No.: 09-01-37-002D Date: September 27, 2010 Subject: Water Leak into Front and Rear Passenger Floor and/or Carpet Wet (Inspect White Plug in HVAC Evaporator Drain and Apply Sealer to Front of Dash Area) Models: 2008-2010 Chevrolet Cobalt 2008-2011 Chevrolet HHR, Malibu 2008-2010 Pontiac G5 2008-2009 Pontiac G6 2008-2009 Saturn AURA Supercede: This bulletin is being revised to add the Pontiac G5 model. Please discard Corporate Bulletin Number 09-01-37-002C (Section 01 - HVAC). Condition Some customers may comment that the front and rear floor carpet is wet on the passenger side. Cause This condition may be caused by a plugged HVAC evaporator Drain. In some cases, water from the HVAC system will drain back though the front of the dash. Correction Note Reposition of the heat shield is not necessary on a Cobalt and HHR. 1. Verify the customer's concern. If there is water on the passenger side front floor area, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Inspect the operation of the drain. Note Make sure that small debris is not plugging up the drain. 3. Reposition the heat shield (1) in order to gain access to the HVAC drain. Locations Trunk / Liftgate Switch: Locations Door Component Views Driver Door Components 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Page 9893 Page 5161 Page 9550 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 3184 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Rear Side Door Window Inner Weatherstrip Replacement Rear Door Weatherstrip: Service and Repair Rear Side Door Window Inner Weatherstrip Replacement Rear Side Door Window Inner Weatherstrip Replacement Page 8928 Grille: Service and Repair Radiator Upper Grille Replacement Radiator Upper Grille Replacement Page 10096 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Page 5125 Page 4195 lever base. 7. Release the transmission range selector lever cable retainer (1). 8. Remove the transmission range selector lever cable grommet (1) from the cowl panel. 9. Remove the transmission range selector lever cable from the vehicle. Installation Procedure Page 6087 Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 6440 Turn Signal/Multifunction Switch X1 Page 3005 Page 5264 Accessory Power Outlet 1. Ignition OFF, remove the X80 accessory power receptacle - 110 V AC. 2. Test for greater than 1 M ohm between terminal 3 and terminal 6. ‹› If less than the specified range, replace the X80 accessory power receptacle - 110 V AC. 3. Test for less than 3 ohm between the following terminals: * The terminal 3 and the applicable receptacle terminal * The terminal 6 and the applicable receptacle terminal ‹› If greater than the specified range, replace the X80 accessory power receptacle - 110 V AC. 4. Test for infinite resistance between terminal 4 and terminal 1. ‹› If not the specified value, replace the X80 accessory power receptacle - 110 V AC. 5. Connect an AC powered device to the X80 accessory power receptacle - 110 V AC. 6. Test for less than 3 ohm between terminal 4 and terminal 1. ‹› If greater than the specified range, replace the X80 accessory power receptacle - 110 V AC. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * 120-Volt Accessory Power Receptacle Replacement (See: Service and Repair/120-Volt Accessory Power Receptacle Replacement) * Control Module References (See: Testing and Inspection/Programming and Relearning) for control module replacement, setup, and programming Page 9871 Page 854 Heated Oxygen Sensor (HO2S) 2 (LAT or LE5 or LE9) Page 4757 Brake Pad: Removal and Replacement Front Disc Brake Pads Replacement Front Disc Brake Pads Replacement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 7. Remove the brake caliper lower guide pin bolt (1). Page 5699 X412 Inline Harness Connector End Views X412 Body Harness to the Right Roof Rail Jumper Harness Service and Repair Power Mirror Motor: Service and Repair Outside Rearview Mirror Motor Replacement Removal Procedure 1. Remove the mirror face. Refer to Outside Rearview Mirror Glass Replacement (See: Service and Repair/Outside Rearview Mirror Glass Replacement). 2. Remove the mirror motor attaching screws. 3. Remove the mirror motor from the mirror housing disconnect the electrical connector. Installation Procedure 1. Position the mirror motor to the mirror housing connector the electrical connector. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Page 1114 The D height dimension measurement determines the proper rear end ride height. There is no adjustment procedure. Repair may require replacement of suspension components. Use the following procedure to check the D dimension: 1. With the vehicle on a flat level surface, lift upward on the rear bumper 38 mm (1.59 in). 2. Gently remove your hands and allow the vehicle to settle. 3. Repeat the jouncing operation 2 more times. 4. Measure the vertical distance from the bottom surface of the floor pan to the top surface of the control arm flange. 5. Repeat this task for the other side of the vehicle. 6. Using your hands, jounce the front of the vehicle downward approximately 38 mm (1.59 in). 7. Gently remove your hands and allow the vehicle to settle. 8. Repeat the jouncing operation 2 more times. 9. Measure the D height dimension. 10. The true D height dimension number is the average of the high and the low measurements. Refer to Trim Height Specifications (See: Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height Specifications). 11. If these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Locations Transmission Position Switch/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components (ME7 or MN5) 1 - Park/Neutral Position (PNP) Switch Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) Page 6337 HVAC Control Module X2 (C68) Service and Repair Positive: Service and Repair Battery Positive Cable Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Loosen the positive battery cable bolt and remove the positive battery cable from the battery. 3. Loosen the positive battery cable bolt at the junction block and remove the cable from the junction block. 4. Remove the positive battery cable clip from the battery tray. 5. Remove the tape holding the negative battery cable to the positive battery cable. 6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 7. Remove the positive battery cable nut (3) from the starter solenoid. 8. Remove the positive battery cable (1) from the starter solenoid. 9. Lower the vehicle. 10. Remove the positive battery cable. Installation Procedure Page 8945 Page 5262 Auxiliary Power Outlet: Testing and Inspection Power Outlet Receptacle Malfunction Power Outlet Receptacle Malfunction Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The accessory DC/AC power inverter module converts 12 V direct current (DC) battery voltage to 110 V at 60 Hertz (Hz) alternating current (AC) in order to operate AC powered devices. The accessory DC/AC power inverter module provides up to 150 watts of power. The accessory DC/AC power inverter module is connected to a chassis ground circuit and receives fuse protected battery voltage. The accessory power receptacle - 110 V AC has an internal switch, that detects when an AC powered device is plugged into the receptacle. When the ignition is ON and an AC powered device is plugged into the accessory power receptacle - 110 V AC, the normally open switch in the accessory power receptacle - 110 V AC, closes. When the accessory DC/AC power inverter module detects the voltage from the accessory power receptacle - 110 V AC switch, the inverter module begins to supply 110 V AC to the accessory power receptacle - 110 V AC after a 1.5 second delay. Reference Information Schematic Reference Cigar Lighter/Power Outlet Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Power Outlets Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Circuit/System Verification Warning Page 6459 2-3 Shift Solenoid (SS) Valve (ME7 or MN5) 4-3 Shift Solenoid (SS) Valve (ME7 or MN5) Page 3519 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. (Intake CMP shown, exhaust CMP similar). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect engine wiring harness electrical connector (5) to the exhaust CMP sensor (4). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 2969 Removal and Replacement Brake Caliper: Removal and Replacement Front Brake Caliper Replacement Front Brake Caliper Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 7. Install a large C-clamp (1) over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. 9. Remove the C-clamp from the caliper. Page 234 Page 1569 Customer TPMS Information Page 10230 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 8 Alarm Module: Service and Repair Theft Deterrent Module Replacement Page 651 Cabin Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Lower (C68) Air Temperature Sensor - Upper (C68) Page 3150 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Locations Control Module HVAC: Locations Instrument Panel/Center Console Component Views Under the Right Side of the Instrument Panel Components 1 - Blower Motor 2 - Blower Motor Control Module (C68) 3 - Blower Motor Resistor (C60) Page 2538 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor - Bank 1 Exhaust (LY7) Camshaft Position (CMP) Sensor - Bank 1 Intake (LY7) Page 4196 1. Install the transmission range selector lever cable to the vehicle. 2. Install the transmission range selector lever cable grommet (1) to the cowl panel. 3. Attach the transmission range selector lever cable retainer (1). Page 4805 Brake Rotor/Disc: Removal and Replacement Front Brake Rotor Replacement Front Brake Rotor Replacement Special Tools * J 41013 Rotor Resurfacing Kit * J 42450-A Wheel Hub Resurfacing Kit Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 4. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. 5. Remove the C-clamp. Service and Repair Fuel Rail: Service and Repair Fuel Injection Fuel Rail Assembly Replacement Removal Procedure 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 3. Disconnect the fuel feed line quick connect fitting (3) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 4. Disconnect the engine wiring harness electrical connector (3) from the fuel injector wiring harness electrical connector (4). Page 716 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 6172 Fuse: Application and ID Fuse Block - Rear Electrical Center Identification Views Fuse Block - Rear Label Page 1379 FUSES ................................................................................................................................................. ..................................................................... USAGE POWER MIRRORS ............................................................................................................................. ...................................................... Power Mirrors EPS ....................................................................... .................................................................................................................... Electronic Power Steering RUN/CRANK ......................................................................................................................... Cruise Control Switch, Passenger Airbag Status Indicator HVAC BLOWER HIGH ............................................................................................ Heating Ventilation Air Conditioning Blower - High Speed Relay CLUSTER/THEFT .............................................................................................................................. Instrument Panel Cluster, Theft Deterrent System ONSTAR .......................................................................................... ...................................................................................................................... OnStar NOT INSTALLED ......................................................................................................................................... .................................................... Not Used AIRBAG (IGN) ................................................................ ...................................................................................................................... Airbag (Ignition) HVAC CTRL (BATT) ................................................................... Heating Ventilation Air Conditioning Control Diagnostic Link Connector (Battery) PEDAL .......................................................................... ...................................................................................................................................... Not Used WIPER SW .......................................................................................................................................... ........................ Windshield Wiper/Washer Switch IGN SENSOR ....................................................... ..................................................................................................................................... Ignition Switch STRG WHL ILLUM ............................................................................................................................................................. Steering Wheel Illumination NOT INSTALLED .................................................................................... ......................................................................................................... Not Used RADIO ....................... .............................................................................................................................................................. .................... Audio System INTERIOR LIGHTS ................................................................................. ................................................................................................. Interior Lamps NOT INSTALLED ...... .............................................................................................................................................................. ......................... Not Used POWER WINDOWS .................................................................................. ............................................................................................. Power Windows HVAC CTRL (IGN) .................................................................................................................. Heating Ventilation Air Conditioning Control (Ignition) HVAC BLOWER ........................................................................................................................... Heating Ventilation Air Conditioning Blower Switch DOOR LOCK ..................................................................................... ............................................................................................................. Door Locks ROOF/HEAT SEAT ................................................................................................................................................... ...................... Sunroof, Heated Seat NOT INSTALLED ...................................................................... ....................................................................................................................... Not Used NOT INSTALLED ......................................................................................................................................... .................................................... Not Used AIRBAG (BATT) ............................................................. ....................................................................................................................... Airbag (Battery) SPARE FUSE HOLDER ...................................................................................................................... ................................................ Spare Fuse Holder SPARE FUSE HOLDER ...................................... ................................................................................................................................ Spare Fuse Holder SPARE FUSE HOLDER .......................................................................................................... ............................................................ Spare Fuse Holder SPARE FUSE HOLDER .......................... ............................................................................................................................................ Spare Fuse Holder Page 8666 Body Control Module (BCM) X3 Page 6908 2. Ensure the steering gear oil seals (1) are fully seated in the steering gear. Caution: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 3. Install the power steering gear inlet hose to the vehicle. 4. Install the steering gear. Refer to Steering Gear Replacement (See: Steering Gear/Service and Repair/Steering Gear Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the power steering gear inlet hose (2) to the steering gear and install the power steering gear inlet hose bolt (1). Prior to tightening the power steering gear inlet hose bolt (1), rotate the power steering gear outlet hose clockwise/downwards so it touches the power steering gear inlet hose (2). Verify the power steering hoses are still touching after the power steering gear inlet hose bolt is tight. Tighten the bolt to 27 Nm (20 lb ft). 6. Connect the power steering gear inlet pipe hose retainers. Page 7671 Hose/Line HVAC: Service and Repair Suction Hose Replacement Suction Hose Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 2. Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs. 3. Remove the compressor hose and liquid line connector. 4. Remove the suction hose from the compressor hose. 5. Remove and discard the O-rings. 6. Remove the surge tank from the surge tank bracket. 7. Remove the suction hose and liquid line nut from the thermal expansion valve (TXV). 8. Remove the suction hose and liquid line from the TXV. Page 2488 1 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 Front and Right Side of the Engine Components (LY7) Page 4602 4T45-E - Automatic Transmission Shift Solenoid: Service and Repair 4T45-E - Automatic Transmission 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions See: Automatic Transmission/Transaxle/Description and Operation. 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of Page 4769 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Tires - Slight/Mild Edge Feathering Information Tires: Technical Service Bulletins Tires - Slight/Mild Edge Feathering Information INFORMATION Bulletin No.: 07-03-10-008B Date: August 13, 2009 Subject: Information on Slight or Mild Tire Feathering and Recommended Practices (Normal Tire Wear Condition) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 07-03-10-008A (Section 03 - Suspension). This bulletin provides information regarding the normal tire wear condition of slight or mild tire feathering and recommended practices. If a vehicle comes into a dealership with a concern of slight or mild feathering-type wear on the tires, review with the customer their past tire rotation history. Tires should be rotated every 8,000 to 13,000 km (5,000 to 8,000 mi) for applicable vehicles with tires where a tire rotation is possible or recommended. Refer to Corporate Bulletin Number 05-03-10-015B for information on tire rotation for vehicles with different front/rear tire/wheel sizes. SOME TIRE FEATHERING IS A NORMAL PART OF TIRE WEAR AND THROUGH PROPER TIRE ROTATION AND INFLATION, THIS TIRE WEAR CAN BE MINIMIZED AND TIRE LIFE MAXIMIZED. If the customer has not rotated the tires within the last 8,000 to 13,000 km (5,000 to 8,000 mi), a tire rotation in the modified X-pattern is necessary to clean-up the feathering, rather than placing the vehicle on the alignment machine. Disclaimer Locations Pedal Positioning Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 6902 Power Steering Line/Hose: Service and Repair Power Steering Fluid Reservoir Outlet Hose Replacement Power Steering Fluid Reservoir Outlet Hose Replacement Removal Procedure 1. Remove as much power steering fluid from the remote power steering fluid reservoir as possible. 2. Place drain pans under the vehicle as needed. 3. Compress the power steering fluid reservoir outlet hose clamp (1) and disconnect the power steering fluid reservoir outlet hose (2) from the remote power steering fluid reservoir (3). 4. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 5. Compress the power steering fluid reservoir outlet hose clamp (1) and disconnect the power steering fluid reservoir outlet hose (2) from the power steering pump (3). Page 7492 3. Install the motor blower seal to the blower motor service ring. 4. Install the blower motor. 5. Install the blower motor attachment ring. 6. Install the blower motor screws and tighten to 1.5 Nm (13 lb in). 7. Install the blower motor wire harness connector. 8. Install the right closeout panel. Refer to Instrument Panel Insulator Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement Right Side). Page 2803 Service and Repair Power Distribution Relay: Service and Repair Relay Replacement Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 3255 Secondary Air Injection (AIR) Pump Solenoid Bank 1 (LZ4 with NU6, or LZE with NU1 or NU5) Page 2867 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wire dress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 5645 Automatic Transmission Auxiliary Fluid Pump (HP7 with ME7) Page 6235 Courtesy Lamp Diagrams Air Injection Pump Relay: Diagrams Component Connector End Views Secondary Air Injection (AIR) Pump Relay (NU6) Page 520 Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3 or HP7) Page 7605 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 9270 Paint: Service Precautions Clearcoat/Ultraviolet Screeners Caution Clearcoat/Ultraviolet Screeners Caution Caution: Removing more than 0.5 mils of the Clearcoat can result in early paint failure. The Clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect. Page 6795 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Page 3566 Camshaft Position (CMP) Sensor - Bank 2 Intake (LY7) Page 3848 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Component Location Component Location Component Locations 1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid Pump Drive Link Assembly 12 - Park Pawl Page 3349 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Inlet Duct Replacement Air Cleaner Inlet Duct Replacement Exploded Views Transmission Speed Sensor: Exploded Views Disassembled Views Disassembled Views Case and Associated Parts (1 of 3) 1 - Side Cover (Structural) 2 - Axle Oil Seal 3 - Side Cover Bolt 4 - Side Cover Stud 5 - Side Cover Gasket 6 - Side Cover Oil Level Control Gasket 7 - Thrust Washer (Side Cover to Driven Sprocket) 8 - Oil Pump Bolt 9 - Oil Pump Bolt 10 - Transaxle Oil Pump Assembly 11 - Transaxle Wiring Assembly 12 - TFP Manual Valve Position Switch Assembly Bolt 13 - TFP Manual Valve Position Switch Assembly 14 - Wiring Harness Pass-Through Connector O-Ring Seal 15 - Wiring Harness Bracket Bolt/Input Speed Sensor Bolt 51 - Transaxle Case 52 - Vent Cap 55 - Torque Converter Assembly 61 - Output Speed Sensor Stud 62 - Output Shaft Speed Sensor 63 - O-Ring Seal (Output Speed Sensor) 64 - Band Anchor Pin (Lo/Reverse) 65 - Oil Level Control Plug 81 - Tube Assembly Bolt/Bottom Pan Bolt 84 - Transaxle Oil Filter Seal Page 10456 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 9185 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 7861 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 3112 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Exhaust Camshaft Position Sensor Replacement - Exhaust Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (5) from the exhaust camshaft position (CMP) sensor (4). 3. Remove the CMP sensor bolt. (Intake CMP shown, exhaust CMP similar). 4. Remove the CMP sensor. Installation Procedure Page 8529 Antenna Control Module: Diagrams Component Connector End Views Radio Antenna Module Page 2467 Knock Sensor: Service and Repair Knock Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (1) from the knock sensor pigtail electrical connector (6). 4. Remove the knock sensor electrical connector pigtail (6) clip from the oil level indicator tube bracket. 5. Remove the knock sensor bolt. 6. Remove the knock sensor. Installation Procedure A/T Controls - Downshift Hesitation/Delayed Shifting Control Module: All Technical Service Bulletins A/T Controls - Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 1119 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the strut to knuckle nuts. Tighten the nuts to 120 Nm (89 lb ft). Page 5544 Side Marker Lamp - Left Front Page 6487 Blower Motor Resistor (C60) Page 6165 Fuse Block - Underhood X2 Page 5402 Camshaft Position (CMP) Sensor - Intake (LAT or LE5 or LE9) Page 9454 Page 5875 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 2796 Page 6193 Fuse Block: Removal and Replacement Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Rear Electrical Center or Junction Block Replacement Rear Electrical Center or Junction Block Replacement OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 9647 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Page 6943 Electric Power Steering (EPS) Module X3 (without NVH) Page 4651 Input Speed Sensor Seal Replacement Page 6270 Engine Control Module (ECM) X1 (LY7) Page 8330 Vehicle Communication Interface Module (VCIM) X3 (UE1) Page 9775 Power Door Lock Switch: Diagrams Component Connector End Views Door Lock Switch - Driver Door Lock Switch - Passenger Page 7457 1. Install the right rear floor duct. 2. Install the floor carpet. Refer to Front Floor Panel Carpet Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Removal and Replacement/Front Floor Panel Carpet Replacement). 3. Install the right center pillar lower garnish molding. Refer to Center Pillar Lower Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Garnish Molding Replacement). 4. Install the right front carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Removal and Replacement/Front Side Door Opening Floor Carpet Retainer Replacement). 5. Install the right front seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Replacement - Bucket). 6. Install the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement Page 1162 * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Spark Plug Visual Inspection * Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak coils Page 9653 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Connector Position Assurance Locks Connector Position Assurance Locks Page 7182 Installation Procedure 1. Position the backing plate and wheel bearing/hub assembly in the steering knuckle. Page 2607 Caution: Do not coat spark plug threads with anti-seize compound. If anti-seize compound is used and spark plugs are over-torqued, damage to the cylinder head threads may result. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the spark plugs and tighten the plugs to 20 Nm (15 lb ft. The spark plug gap is 1.0 mm (0.040 in). 2. Install the ignition coil(s). Refer to Ignition Coil Replacement (See: Ignition System/Ignition Coil/Service and Repair). Page 7297 Tires: Description and Operation P-Metric Sized Tires Description P-Metric Sized Tires Description Most P-metric tire sizes do not have exact corresponding alphanumeric tire sizes. Replacement tires should be of the same tire performance criteria TPC specification number including the same size, the same load range, and the same construction as those originally installed on the vehicle. Consult a tire dealer if you must replace the P-metric tire with other sizes. Tire companies can best recommend the closest match of alphanumeric to P-metric sizes within their own tire lines. The above illustration may not correspond with your vehicle, but is meant as an example. Page 9700 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Locations Turn Signal Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 3602 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure Caution: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage. 1. Remove the ignition coil(s). Refer to Ignition Coil Replacement (See: Ignition Coil/Service and Repair). Note: Make sure that any water and/or debris is blown out of the spark plug holes prior to removing the spark plugs. 2. Remove the spark plugs using a 5/8 inch spark plug socket. Installation Procedure Page 3111 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (7) to the intake CMP sensor (6). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 953 Page 6046 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 5612 Turn Signal/Multifunction Switch X2 Page 6623 Page 5042 Page 4390 4. Crimp the eared clamp (6) using J 35910, a torque wrench (8), and a breaker bar (9). 5. If equipped, install the spacer ring (2) into the groove of the halfshaft bar using J 8059. Page 6276 Engine Control Module (ECM) X2 (LE5 or LE9) Page 2603 Spark Plug: Testing and Inspection Spark Plug Inspection Spark Plug Usage * Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications (See: Ignition System/Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling - colder plug - Pre-ignition causing spark plug and/or engine damage - hotter plug Spark Plug Inspection * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. * Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 9427 Seat Back: Service and Repair Rear Seat Back Cushion Replacement Rear Seat Back Cushion Replacement Page 3630 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Component Location Component Location Component Locations 1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid Pump Drive Link Assembly 12 - Park Pawl Page 469 Page 2003 30. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal. 31. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head. Note: Ensure the timing chain tensioner seal is centered throughout the torque procedure to eliminate the possibility of an oil leak. 32. Install the timing chain tensioner assembly. Tighten the timing chain tensioner to 75 Nm (55 lb ft). 33. The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner. 34. Using a 24 mm wrench, engage the hex on the intake camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten the intake camshaft position actuator bolt to 30 Nm (22 lb ft) plus 100 degrees using the EN-45059 - meter. 35. Using a 24 mm wrench, engage the hex on the exhaust camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten the exhaust camshaft position actuator bolt to 30 Nm (22 lb ft) plus 100 degrees using the EN-45059 - meter. Page 2490 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY7 or LZ4 or LZE) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LY7 or LZ4 or LZE) Diagrams Courtesy Lamp: Diagrams Component Connector End Views Courtesy Lamp Courtesy Lamp - Left Front Door Page 1540 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Locations Fuel Pump Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 5792 Fuse Block - Rear X2 Page 25 Disclaimer Specifications Firing Order: Specifications Ignition System Specifications Page 9926 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 227 Fuse Block - Underhood Top View (LE5 or LE9) Page 2921 4. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the open circuit. 5. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * An open/high resistance on the serial data circuit between 2 control modules * An open/high resistance on the serial data circuit between a control module and a terminating resistor * An open/high resistance terminating resistor Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * Control Module References (See: Testing and Inspection/Programming and Relearning) for control module replacement, setup, and programming Scan Tool Does Not Communicate with Low Speed GMLAN Device Scan Tool Does Not Communicate with Low Speed GMLAN Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The serial data is transmitted over a single wire to the appropriate control modules. The transmission speed for GMLAN low speed is up to 83.33 Kb/s. Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. The control modules toggle the serial data circuit between 0-5 V during normal communications. To wake the control modules connected to the GMLAN low speed serial data circuit, a voltage wake up pulse of 10 V is sent out. If serial data is lost, control modules will set a no communication code against the non-communicating control module. Note: a loss of serial data communications DTC does not represent a failure of the module that set it. Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-ofcommunication U-codes such as these can set for a variety of reasons. Many times, they're transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. Page 3862 Automatic Transmission/Control Valve Body Cover Replacement). 13. If a NEW TCM has been installed into the vehicle, the NEW module needs to be reprogrammed. Refer to Service Programming System (SPS) ( See: Testing and Inspection/Programming and Relearning/Service Programming System (SPS)). Note: The Service Fast Learn Adapts procedure must be performed when one of the following repairs have been made to the vehicle. Failure to perform the procedure after one of the following repairs may result in poor transmission performance, as well as transmission DTCs being set: * Transmission internal service/overhaul * Valve body repair or replacement * Control solenoid valve assembly replacement * TCM software/calibration update * Any service in response to a shift quality concern 14. Perform the Service Fast Learn Adapts. Refer to Service Fast Learn Adapts (See: Testing and Inspection/Programming and Relearning/6T70/6T75 - Automatic Transmission). Locations Power Distribution Module: Locations Luggage Compartment/Rear of Vehicle Component Views Rear Window Shelf Components 1 - Cellular (UE1) and Digital Radio Antenna (U2K) 2 - Radio Antenna Module 3 - Remote Start Antenna (AP3) 4 - Speaker - Right Rear 5 - Accessory AC/DC Power Control Module (KV1) 6 Audio Amplifier (UQ3) 7 - Rear Compartment Courtesy Lamp 8 - Remote Control Door Lock Receiver (RCDLR) 9 - Digital Radio Receiver (U2K) 10 - Speaker - Left Rear Page 6489 Page 8229 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Page 2909 * J-38125-8 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Sunshade Anchor Replacement Sun Visor: Service and Repair Sunshade Anchor Replacement Sunshade Anchor Replacement Brake Pedal Position Sensor Calibration Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Calibration Brake Pedal Position Sensor Calibration Calibration Criteria Important: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor (BPPS) calibration must be repeated. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or body control module (BCM) have been serviced. The calibration procedure will set the brake pedal position sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via the GMLAN communication bus. Calibration Procedure 1. Apply the parking brake. 2. Place the transmission in the PARK position. 3. Install a scan tool. 4. Clear all BCM DTCs before proceeding. 5. Navigate to the Vehicle Control Systems menu. 6. Select Module Setup menu item. 7. Select BCM menu item. 8. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen. Page 5629 1-2 Shift - Br Component Connector End Views 1-2 Shift Solenoid (SS) Valve (ME7 or MN5) Page 4455 Transmission Control Module (TCM) (MN5 with LE5 or LE9) Page 5129 Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 583 Note: Ensure the gasket on the outside barrel of the master cylinder is positioned properly and is free of cuts and tears. 4. Install the brake master cylinder to the booster assembly. Refer to Master Cylinder Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement). A/C - Front/Rear Passenger Carpet Wet Housing Assembly HVAC: All Technical Service Bulletins A/C - Front/Rear Passenger Carpet Wet TECHNICAL Bulletin No.: 09-01-37-002D Date: September 27, 2010 Subject: Water Leak into Front and Rear Passenger Floor and/or Carpet Wet (Inspect White Plug in HVAC Evaporator Drain and Apply Sealer to Front of Dash Area) Models: 2008-2010 Chevrolet Cobalt 2008-2011 Chevrolet HHR, Malibu 2008-2010 Pontiac G5 2008-2009 Pontiac G6 2008-2009 Saturn AURA Supercede: This bulletin is being revised to add the Pontiac G5 model. Please discard Corporate Bulletin Number 09-01-37-002C (Section 01 - HVAC). Condition Some customers may comment that the front and rear floor carpet is wet on the passenger side. Cause This condition may be caused by a plugged HVAC evaporator Drain. In some cases, water from the HVAC system will drain back though the front of the dash. Correction Note Reposition of the heat shield is not necessary on a Cobalt and HHR. 1. Verify the customer's concern. If there is water on the passenger side front floor area, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Inspect the operation of the drain. Note Make sure that small debris is not plugging up the drain. 3. Reposition the heat shield (1) in order to gain access to the HVAC drain. Page 336 Engine Control Module (ECM) X2 (LAT) Page 3536 Ignition Coil 4 (LY7) Page 1272 6. Remove the power steering fluid reservoir outlet hose from the vehicle. Installation Procedure 1. Position the power steering fluid reservoir outlet hose to the vehicle. 2. Compress the power steering fluid reservoir outlet hose clamp (1) and connect the power steering fluid reservoir outlet hose (2) to the power steering pump (3). 3. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 4. Compress the power steering fluid reservoir outlet hose clamp (1) and connect the power steering fluid reservoir outlet hose (2) to the remote power steering fluid reservoir (3). 5. Clean any excess power steering fluid from the vehicle and remove the drain pans. 6. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair). Page 1441 Page 7456 Floor Rear Air Outlet Duct Replacement - Right Side Removal Procedure 1. Remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 2. Remove the right front seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Replacement - Bucket). 3. Remove the right front carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Removal and Replacement/Front Side Door Opening Floor Carpet Retainer Replacement). 4. Remove the right center pillar lower garnish molding. Refer to Center Pillar Lower Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Garnish Molding Replacement). 5. Remove the floor carpet enough to access the right rear floor duct. Refer to Front Floor Panel Carpet Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Removal and Replacement/Front Floor Panel Carpet Replacement). 6. Remove the left rear floor duct. Installation Procedure Page 6382 Park/Turn Signal Lamp - Left Page 8214 Page 5907 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 4002 Parking Lock Cable: Service and Repair 6T70/6T75 - Automatic Transmission Park Lock Cable Replacement Removal Procedure 1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 3. Place the transmission shift control lever in the PARK position. 4. Remove the park lock cable end (1) from the park lock lever by sliding the cable end rearward off the park lock lever pin. 5. Release the park lock cable retainer (2) from the shift control base. 6. Remove the knee bolster. Refer to Driver Knee Bolster Panel Replacement (See: Restraint Systems/Knee Diverter/Service and Repair). 7. Turn the ignition key to the RUN position. Page 5422 Dome/Reading Lamps Page 9554 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors Tyco/AMP Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 5474 Fuel Injector 5 (LZ4 or LZE) Page 9522 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Page 9689 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 9916 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Page 9690 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 899 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor - Bank 1 Exhaust (LY7) Camshaft Position (CMP) Sensor - Bank 1 Intake (LY7) Page 4827 9. Remove the brake hose to caliper bolt from the brake caliper. 10. Remove the brake hose from the brake caliper. 11. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end. 12. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 13. Remove the 2 brake caliper pin bolts. Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Center Console Components 1 - Automatic Transmission Shift Lock Control Solenoid 2 - Automatic Transmission Shift Lever Position Indicator Page 6608 Fuse Block - Underhood X2 Page 1177 Drive Belt: Service Precautions Belt Dressing Caution Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Page 6187 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Luggage Compartment/Rear of Vehicle Component Views Left Side of the Luggage Compartment Components Page 6612 Fuse Block - Underhood X4 Page 6949 1 - Steering Wheel Position Sensor (NVH) Page 3038 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 3330 ‹› If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump Electrical Circuit Diagnosis). 2. Ignition OFF, all accessories OFF, install a CH 48027 - Pressure Gauge. Refer to Fuel Pressure Gauge Installation and Removal (See: Fuel Pressure Gauge Installation and Removal). 3. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and does not decrease more than 34 kPa (5 psi) in 1 minute. Circuit/System Testing Note: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel pressure gauge while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Install the J 37287 - Shut-off Adapter or the J 37287-FF Adapter between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 - Shut-off Adapter or the J 37287-FF - Adapter. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the CH 48027 - Gauge. 5. Command the fuel pump relay ON and then OFF with a scan tool. 6. Close the valve on the J 37287 - Shut-off Adapter or the J 37287-FF Adapter. 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injectors. ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with the CH 48027 - Gauge. The fuel pressure should not drop off during acceleration, cruise, or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Line Replacement - Chassis (See: Fuel Supply Line/Service and Repair) * Fuel Injector Replacement (See: Fuel Injector/Service and Repair) * Fuel Tank Fuel Pump Module Replacement (See: Fuel Pump/Service and Repair) Page 8500 Warranty Information (Saab U.S. Models) Disclaimer Page 1436 Page 6540 Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor Replacement - Intake Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (7) from the intake camshaft position (CMP) sensor (6). 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. Installation Procedure Page 3523 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LAT or LE5 or LE9) Crankshaft Position (CKP) Sensor (LY7) Locations Backup Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 5157 Page 4792 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Brake Rotor Assembled Lateral Runout Correction Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. * The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. Refer to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled Lateral Runout Correction - Indexing). * The correction plate method of correcting assembled LRO involves the addition of a tapered plate between the brake rotor and the hub/axle flange. The correction plate method can be used to correct LRO that exceeds the specification by up to 0.23 mm (0.009 in). Refer to Brake Rotor Assembled Lateral Runout Correction - Correction Plates (See: Brake Rotor Assembled Lateral Runout Correction - Correction Plates). * The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe). If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Brake Rotor Assembled Lateral Runout Correction - Correction Plates Brake Rotor Assembled Lateral Runout Correction - Correction Plates Special Tools * CH-39544-KIT - Complete Torque Socket Set - 10 PCS, or equivalent * CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Driver or Passenger Seat Back Cushion Cover and Pad Replacement Seat Back: Service and Repair Driver or Passenger Seat Back Cushion Cover and Pad Replacement Driver or Passenger Seat Back Cushion Cover and Pad Replacement Page 1396 Page 7539 4. If replacing the condenser, add the specific amount of PAG(R) oil directly to the condenser. Refer to Refrigerant System Specifications (See: Refrigerant/Specifications). 5. Install the radiator air side seals onto the condenser mounting tabs on the radiator. 6. Insert condenser mounting tabs into the radiator clips. Caution: The bolt retaining the condenser to the radiator end tank is a special length and should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank. Note: Replace the condenser mounting bolts and nuts. 7. Install the condenser mounting nuts. Page 7544 25. Install both upper radiator support brackets. Note: Do not allow the upper bracket to twist when tightening the radiator mounting bolts or vibration may result. 26. Install both upper radiator support bracket bolts and tighten to 10 Nm (89 lb in). 27. Install the left and right headlamp assemblies. Refer to Headlamp Replacement (See: Lighting and Horns/Headlamp/Service and Repair/Removal and Replacement). 28. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 29. Leak test the fittings using the J 39400-A. Page 2676 Camshaft Position (CMP) Sensor - Intake (LAT or LE5 or LE9) Page 9895 Page 9774 1 - Outside Rearview Mirror - Passenger 2 - Door Frame 3 - Door Latch - Passenger 4 - Inflatable Restraint Side Impact Sensor (SIS) - Right 5 - Window Switch - Passenger 6 - Speaker - Right Front 7 - Window Motor - Passenger 8 - Door Lock Switch - Passenger 9 - Courtesy Lamp - Right Front Door Page 4963 Electronic Brake Control Module (EBCM) (LE5 or LE9) Page 5562 Recirculation Actuator (C68) Remote Control Door Lock Receiver (RCDLR) Page 7006 Steering Gear: Service and Repair Steering Gear Cylinder Pipe Assembly and Seals Replacement - Off Vehicle Steering Gear Cylinder Pipe Assembly and Seals Replacement - Off Vehicle Removal Procedure 1. Hoist the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Place drain pans under the vehicle as needed. Note: Protect the steering gear boots from sharp tools and from the sharp edges of surrounding components. 3. Remove the steering gear cylinder pipe retaining plate bolt (1) and retaining plate (2). 4. Loosen the steering gear cylinder pipe fittings (3, 4). 5. Remove both steering gear cylinder pipes from the steering gear (1). 6. Remove and discard the steering gear cylinder pipe seals (4) from the steering gear at the valve end (5). Installation Procedure 1. Inspect the steering gear cylinder pipes (1) for the following items: * Cracks * Dents * Damage to the threads 2. Replace the steering gear cylinder pipes (1) as needed. Page 1011 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (ME7 or MN5) Page 5258 Page 6513 Locations Crankshaft Position Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 9861 Page 4972 Brake Booster Vacuum Sensor: Diagrams Component Connector End Views Brake Booster Vacuum Sensor (LAT) Driver or Passenger Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Knob Replacement Driver or Passenger Seat Adjuster Switch Knob Replacement Page 2905 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the MYLAR tape. If the MYLAR tape is damaged, use 3M product AL-36FR to replace the damaged MYLAR tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Page 140 Page 1046 Automatic Transmission Output Shaft Speed (OSS) Sensor (ME7 or MN5) Locations Power Distribution Module: Locations Luggage Compartment/Rear of Vehicle Component Views Rear Window Shelf Components 1 - Cellular (UE1) and Digital Radio Antenna (U2K) 2 - Radio Antenna Module 3 - Remote Start Antenna (AP3) 4 - Speaker - Right Rear 5 - Accessory AC/DC Power Control Module (KV1) 6 Audio Amplifier (UQ3) 7 - Rear Compartment Courtesy Lamp 8 - Remote Control Door Lock Receiver (RCDLR) 9 - Digital Radio Receiver (U2K) 10 - Speaker - Left Rear Radiator Inlet Hose Replacement Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement Page 6488 Body Control Module (BCM) X1 Page 4932 1. Install the park brake warning lamp switch (2) to the park brake pedal assembly (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch screw (3) and tighten to 2 Nm (18 lb in). 3. Connect the electrical connector to the park brake warning lamp switch. 4. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 5. Check the operation of the park brake warning lamp switch. Page 9810 Trunk / Liftgate Switch: Service and Repair Rear Compartment Lid Release Switch Replacement Page 1033 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Page 537 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Passenger Front Door Lock Switch Replacement - Passenger Front Page 5989 Diagrams Front Door Latch: Diagrams Component Connector End Views Door Latch - Driver Door Latch - Left Rear Page 4532 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Remove the automatic transaxle control assembly. 2. Disconnect the Shift Lock Control Solenoid connector from the solenoid. 3. Using a flat-blade screwdriver or similar tool pry the solenoid off of the ball-sockets on the solenoid plunger and solenoid body. Page 4779 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Page 4062 3. Remove the snap ring from the stub axle shaft. Discard the snap ring. Do not reuse. 4. Install the J 38868 and J 6125-1B into the stub shaft snap ring groove. 5. Pull lightly on the shaft while rotating the shaft until the stub shaft snap ring at the differential seats in the taper on the differential side gear. 6. Remove the stub shaft from the transmission. Page 3276 5. Remove the lower right HO2S (2) using the J 39194-B. 6. Remove the left (front) catalytic converter to right (rear) catalytic converter nuts (3). 7. Remove the right (rear) catalytic converter bolt (5) and nuts (1) at the exhaust manifold. 8. Remove the right catalytic converter (2). 9. Remove and discard the gasket (6). 10. Inspect the catalytic converter-to-exhaust manifold flange. * Service Limit: 0.7 mm (0.028 in) max. * Standard: 0.7 mm (0.028 in) max. Installation Procedure Page 1310 Fluid - A/T: Service Precautions Checking Hot Transmission Fluid through Drain Plug Hole Warning Warning The engine must be running when the transmission fluid fill plug is removed, or excessive fluid loss will occur. Transmission fluid may be hot. Since the actual fluid level is unknown, stand clear when removing the fill plug. Have a container ready to capture any lost fluid. Do not turn the engine off with the fill plug removed, as you can be injured by hot transmission fluid being expelled out of the oil fill opening. Page 6009 Page 4987 Brake Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Pressure Sensor (LAT) Diagrams Keyless Entry Receiver: Diagrams Component Connector End Views Remote Control Door Lock Receiver (RCDLR) Locations Hood Sensor/Switch (For Alarm): Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (2 of 2) 1 - Hood Ajar Switch (AP3) Page 1109 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Page 8506 Warranty Information (Saab U.S. Models) Disclaimer Page 4346 * The 2-3 shift solenoids (305) (white connectors) * The TCC solenoid (335) 2. Install the control valve body. 3. Install the transmission side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 4. Reset the TAP values. Refer to Transmission Adaptive Functions See: Description and Operation. 5. Install the transmission. Page 5135 Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 5494 Heated Seat Control Module - Driver X1 (KA1) Page 5676 X108 Engine Harness to the Body Harness (LZ4 or LZE) Locations Combination Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Locations Steering Angle Sensor: Locations Steering Column Disassembled View 1 - Intermediate Steering Shaft 2 - Intermediate Steering Shaft Bolt 3 - Steering Wheel Position Sensor 4 - Steering Column 5 - Tilt Lever Spring 6 - Tilt Lever Nut 7 - Tilt Lever Bearing 8 - Tilt Lever Spacer 9 - Tilt Lever Retainer 10 - Tilt Lever Retainer 11 - Tilt Lever Cam 12 - Tilt Lever Follower 13 - Tilt Lever 14 - Tilt Lever Spring 15 - Intermediate Steering Shaft Nut Instrument Panel/Center Console Component Views Behind Left Side of the Instrument Panel Components Page 5778 Page 6922 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Use a M6x1 TORX(R) head bit in order to install the power steering assist motor bolts (1) and tighten to 9 Nm (80 lb in). 4. Connect the power steering assist motor sensor wire harness (3) to the power steering assist motor (2). 5. Install the power steering assist motor sensor wire harness strap clip (4) to the power steering assist motor. 6. Perform the control module setup. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Page 946 Seat Belt Buckle Switch: Diagrams Component Connector End Views Seat Belt Switch - Driver Seat Belt Switch - Passenger Page 6053 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 2682 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. (Intake CMP shown, exhaust CMP similar). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect engine wiring harness electrical connector (5) to the exhaust CMP sensor (4). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 9724 Page 10773 Windshield Washer Reservoir: Service and Repair Windshield Washer Solvent Container Hose Replacement Windshield Washer Solvent Container Hose Replacement Removal Procedure 1. Open the hood. 2. Disconnect the solvent container washer hose (1) from the windshield washer hose (2) and disengage the hose from the solvent container clips. 3. Route the hoses downward to allow draining. 4. Drain the washer solvent from the washer solvent container. 5. Remove the front wheelhouse panel splash shield. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 6. Disconnect the washer hose (1) and electrical harness from the washer pump (2). Page 794 Specifications Firing Order: Specifications Ignition System Specifications Specifications Brake Fluid: Specifications Hydraulic Brake System: DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 88862806, in Canada 88862807). Page 2525 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 4202 8. Remove the transmission range selector lever cable grommet (1) from the cowl panel (2). 9. Remove the transmission range selector lever cable from the vehicle. Installation Procedure 1. Install the transmission range selector lever cable to the vehicle. 2. Install the transmission range selector lever cable grommet (1) to the cowl panel (2). Page 6295 Fog Lamp - Right Front (T96) Page 2950 Locations Seat Belt Buckle Switch: Locations Passenger Compartment/Roof Component Views Seat Components - Driver 1 - Seat Back Cover - Driver 2 - Heated Seat Element - Driver Back (KA1) 3 - Seat Back Cushion Pad - Driver 4 - Seat Recline Motor - Driver (1LZ) 5 - Seat Horizontal Motor - Driver (AG1 or 1LZ) 6 - Seat Rear Vertical Motor - Driver (AG1 or 1LZ) 7 - Heated Seat Control Module - Driver (KA1) 8 Seat Front Vertical Motor - Driver (AG1 or 1LZ) 9 - Seat Recline Switch - Driver (1LZ) 10 - Seat Adjuster Switch - Driver 11 - Seat Belt Switch - Driver 12 - Seat Cushion - Driver 13 - Heated Seat Element - Driver Cushion (KA1) 14 - Seat Cover - Driver Seat Components - Passenger Page 9629 Page 9951 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Locations Battery Control Module: Locations Luggage Compartment/Rear of Vehicle Component Views Lower Front of the Rear Compartment Components (HP7) 1 - Generator Battery 1 2 - Generator Battery Temperature Sensor 1A 3 - Generator Battery Temperature Sensor 1B 4 - Generator Battery 2 5 - Generator Battery Temperature Sensor 2A 6 Generator Battery Temperature Sensor 2B 7 - Generator Battery 3 8 - Generator Battery Temperature Sensor 3A 9 - Generator Battery Temperature Sensor 3B 10 - Generator Battery Vent Fan 11 - Battery Current Sensor 12 - Main Contactor Relay 13 - Battery Disconnect Switch 14 Generator Battery Disconnect Control Module Page 8182 Page 6083 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools Page 6807 Alignment: Description and Operation Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Page 3593 Knock Sensor: Service and Repair Knock Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (1) from the knock sensor pigtail electrical connector (6). 4. Remove the knock sensor electrical connector pigtail (6) clip from the oil level indicator tube bracket. 5. Remove the knock sensor bolt. 6. Remove the knock sensor. Installation Procedure Page 1912 16. Remove the oil pan 17. Remove any old oil pan sealant (1). Installation Procedure 1. Ensure that the oil pan and the sealing surface on the lower crankcase are free of all oil and debris. 2. Apply a 2 mm bead of sealant (1) around the perimeter of the oil pan and the oil suction port opening. DO NOT over apply the sealant. More than a 2 mm bead is not required. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). 3. Install the oil pan. Page 2865 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 8719 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Water Deflector Replacement Air Inlet Grille Panel Water Deflector Replacement Page 2262 7. Remove the heat shield. Installation Procedure 1. Position the heat shield to the underbody and the dash panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heat shield nuts and tighten to 10 Nm (89 lb in). 3. Install the left frame reinforcement (3). 4. Install the left frame bolts (4). Tighten the bolts to 100 Nm (74 lb ft) plus an additional 90 degrees using the J-45059 - meter. 5. Raise the muffler pipe into position and install the first two muffler insulators onto the hangers. 6. If equipped with a 3.5L or 3.6L engine, install the catalytic converters. Refer to Catalytic Converter Replacement - Left Side (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Left Side) and Catalytic Converter Replacement - Right Side (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Right Side). 7. If equipped with a 2.4L engine, install the exhaust manifold pipe. Refer to Catalytic Converter Replacement (See: Catalytic Converter/Service Page 9905 Cruise Control: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 2908 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools Page 2356 Service and Repair Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement Page 1024 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement Special Tools J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. Warning Page 10768 1. Position the washer pump terminal seal (6) to the washer solvent container (1), pressing in until fully seated. 2. Using full strength windshield washer solvent as a lubricant on the terminal seal, position the washer pump (5) to the washer solvent container (1) pressing in until fully seated. 3. Connect the washer pump electrical connector. 4. Connect the washer pump hose (2) to the washer pump (5). 5. Install the front wheelhouse panel splash shield. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 6. Fill the washer solvent container with washer solvent. 7. Inspect the washer system for proper operation. Page 2578 ‹› If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump Electrical Circuit Diagnosis). 2. Ignition OFF, all accessories OFF, install a CH 48027 - Pressure Gauge. Refer to Fuel Pressure Gauge Installation and Removal (See: Fuel Pressure Gauge Installation and Removal). 3. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and does not decrease more than 34 kPa (5 psi) in 1 minute. Circuit/System Testing Note: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel pressure gauge while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Install the J 37287 - Shut-off Adapter or the J 37287-FF Adapter between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 - Shut-off Adapter or the J 37287-FF - Adapter. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the CH 48027 - Gauge. 5. Command the fuel pump relay ON and then OFF with a scan tool. 6. Close the valve on the J 37287 - Shut-off Adapter or the J 37287-FF Adapter. 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injectors. ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with the CH 48027 - Gauge. The fuel pressure should not drop off during acceleration, cruise, or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Line Replacement - Chassis (See: Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair) * Fuel Injector Replacement (See: Fuel Delivery and Air Induction/Fuel Injector/Service and Repair) * Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) Page 1582 Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Page 980 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Page 4559 2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid valve spring (7) into position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Install all bolts before tightening, then tighten in specified sequence. 4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x 55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6 x 42. 8. Install the 2 control valve body bolts (4) M6 x 65 and tighten to 12 Nm (106 lb in). 9. Connect the input speed sensor electrical connector (1). 10. Connect the output speed sensor electrical connector (2). 11. Connect the shift position switch electrical connector (3). 12. Install the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Page 3268 5. Remove the exhaust manifold heat shield bolts and shield. 6. Remove the left (front) catalytic converter nuts (1) at the exhaust manifold. 7. Remove the muffler assembly. Refer to Exhaust Muffler Replacement (See: Engine, Cooling and Exhaust/Exhaust System/Muffler/Service and Repair). Page 7963 Note DO NOT replace the sensing and diagnostic module (SDM), side sensors or air bag modules. Note Both driver and passenger seats must be repaired when this concern occurs even if only one DTC code is set. The service kit contains sufficient components to repair both seat connectors. Connector Replacement Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above includes harness and connector clips, which are not required in this installation. Replace connectors on both driver and passenger seats, and then reposition the connectors following the steps below. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Note Only use hand tools to remove the seat to floor mounting bolts. If there are any problems with bolt removal, refer to Corporate Bulletin Number 10-08-50-002. 2. Remove the driver's seat to floor mounting bolts. Loosen the seat from the front retainers and tilt it back to expose the underside of the seat. Refer to Front Seat Replacement - Bucket in SI. Page 1285 7. Install the 2 power steering gear outlet pipe hose retainers (1) to the right side of the front frame. 8. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 9. Compress the power steering gear outlet hose clamp (1) and connect the power steering gear outlet hose (3) to the power steering reservoir inlet pipe (2). 10. Clean any excess power steering fluid from the vehicle and remove the drain pans. 11. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). 12. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair). Page 4267 Transmission Front Mount Replacement Transmission Front Mount Replacement Page 3090 Page 1424 Page 9552 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 2280 Disclaimer Page 2963 1 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 Front and Right Side of the Engine Components (LY7) Page 4938 Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Vacuum Sensor Replacement Page 8514 Speaker - Right Rear (UQA) Speaker - Right Rear (UQ3) Page 8581 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 3852 Shift Solenoid: Connector Views Component Connector End Views 1-2 Shift Solenoid (SS) Valve (ME7 or MN5) 2-3 Shift Solenoid (SS) Valve (ME7 or MN5) Page 5990 Page 9267 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 5659 Body Control Module (BCM) X1 Page 8287 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 6151 Page 9948 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 2459 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor (2). 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2). Installation Procedure Page 2859 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Diagram Information and Instructions Cruise Control: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Page 1145 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Inlet Duct Replacement Air Cleaner Inlet Duct Replacement Page 7694 Housing Assembly HVAC: Service and Repair Air Conditioning and Heater Module Assembly Removal and Installation Removal Procedure 1. Remove the air conditioner (A/C) lines from the thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement (See: Expansion Block/Orifice Tube/Service and Repair/Air Conditioning Evaporator Thermal Expansion Valve Replacement). 2. Remove the heater hose from the heater core. Refer to Heater Inlet Hose Replacement (See: Heater Hose/Service and Repair/Heater Inlet Hose Replacement) and Heater Outlet Hose Replacement (See: Heater Hose/Service and Repair/Heater Outlet Hose Replacement). 3. Remove the instrument panel (I/P) assembly. Refer to Instrument Panel Reinforcement Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Reinforcement Replacement). 4. Remove the recirculation actuator wire harness connector. 5. Remove the air temperature actuator wire harness connector. 6. Remove the mode actuator wire harness connector. 7. Remove the blower motor wire harness connector. 8. Remove the blower motor resistor wire harness connector. 9. Remove the left hand side window defogger outlet duct. Page 5599 Sunshade - Right (LTZ) Tail/Stop and Turn Signal Lamp - Left (without LTZ) Page 5797 Page 2774 1. Set the ECM (2) into the bottom of the bracket and push the ECM towards the battery until the ECM snaps into place and is secured by the retainers (1). 2. Connect the engine wiring harness electrical connectors (2) to the ECM. 3. Install the engine wiring harness clips (3) to the ECM bracket (4). Page 9637 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Page 5424 Door Latch - Passenger Page 9639 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Page 2552 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LAT or LE5 or LE9) Crankshaft Position (CKP) Sensor (LY7) Page 9407 Power Seat Motor: Service and Repair Driver Seat Outer Adjuster Rear Vertical Actuator Replacement Driver Seat Outer Adjuster Rear Vertical Actuator Replacement Page 10078 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wire dress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 4878 32. Inspect the brake pipe flare for correct shape and diameter (a). * 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe * 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe * 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe 33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool. Note: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components. 34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required. 35. If previously released, secure the brake pipe to the retainers. 36. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding). 37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes. Page 1675 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 873 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement Special Tools J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. Warning Page 7841 Disclaimer Service Procedure Service Procedure Air Bag Connector Inspection 1. Move the driver's seat to the maximum forward position and raise the seat to its maximum height. 2. Using a flash light, locate the air bag and body wire harnesses. Note Vehicles that have new air bag connectors will have a tie strap securing the two (2) wires exiting the air bag connector to the main body wiring harness. In addition, the new air bag connectors will have an orange connector position assurance (CPA) clip that is tethered to the connector. Ensure both the orange CPA clip and tie strap are located. Air bag and body wire harnesses without the tie strap and/or CPA clip must have the air bag connectors replaced. 3. Determine if the new air bag connectors have been installed. - If the vehicle is equipped with the new air bag connectors, no further action is required. Refer to Warranty Transaction Information in this bulletin. - If the vehicle is NOT equipped with the new air bag connectors, replace the air bag connectors. Refer to Replace Wire Harness Connector in this bulletin. Replace Wire Harness Connector Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. (Seat shown out-of-vehicles for illustration purposes) Page 9667 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 2898 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Page 5674 X102 Right Front Wheel Speed Sensor Harness to Body Harness X108 Inline Harness Connector End Views X108 Engine Harness to Body Harness (LAT) Page 7221 Customer TPMS Information Page 2362 Campaign - Airbag Readiness Light/Service Airbag Message Technical Service Bulletin # 10085D Date: 110203 Campaign - Airbag Readiness Light/Service Airbag Message CUSTOMER SATISFACTION Bulletin No.: 10085D Date: February 03, 2011 Subject: 10085D - Airbag Readiness Light/Service Airbag Message - Replace Connectors Models: 2008 Buick Enclave 2010 Chevrolet Malibu 2008 GMC Acadia 2010 Pontiac G6 2008 Saturn OUTLOOK Supercede: The Service Procedure in this bulletin has been revised. All vehicles will not require the replacement of the front seat-mounted side impact airbag connectors.Please discard all copies of bulletin 10085C, issued November 2010. Condition Certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may experience wear which could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact air bag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG System warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG System DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Correction Dealers are to replace the front seat-mounted side impact airbag connectors. Vehicles Involved Involved are certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Part Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your Page 4334 Valve Body: Service and Repair 6T70/6T75 - Automatic Transmission Control Valve Body Cover Replacement Control Valve Body Cover Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the left engine splash shield. Refer to Engine Splash Shield Replacement - Left Side (See: Body and Frame/Splash Guard/Service and Repair/Engine Splash Shield Replacement - Left Side). 4. Remove the front air dam. Refer to Front Air Deflector Replacement (See: Body and Frame/Spoilers, Flaps, and Air Dams/Air Dam/Service and Repair/Front Air Deflector Replacement). 5. Remove the front transmission mount. Refer to Transmission Front Mount Replacement (See: Transmission Mount/Service and Repair/6T70/6T75 - Automatic Transmission/Transmission Front Mount Replacement). 6. Drain the transmission. Refer to Transmission Fluid Replacement (See: Service and Repair/Removal and Replacement/6T70/6T75 - Automatic Transmission/Transmission Fluid Replacement). 7. Remove the wire harness retainer (2) from the control valve body cover stud. 8. Disconnect the control valve body transmission control module (TCM) electrical connector (1). Page 7042 4. Remove the intermediate steering shaft lower bolt at the steering gear. Discard the bolt. 5. Disconnect the intermediate steering shaft from the steering gear. 6. Remove the left side instrument panel insulator. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 7. Remove the intermediate steering shaft bolt at the steering column. Discard the bolt. 8. Disconnect the intermediate steering shaft from the steering column. Page 8936 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 3096 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (LAT or LE5 or LY7 or LE9) Page 4453 Control Module: Diagrams Component Connector End Views Automatic Transmission Auxiliary Fluid Pump Control Module (HP7 with ME7) Transmission Control Module (TCM) (ME7) Locations Blower Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (except LAT) Service and Repair Front Door Window Regulator: Service and Repair Front Side Door Window Regulator Replacement Page 866 Throttle Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 5526 Inflatable Restraint Sensing and Diagnostic Module (SDM) Alcohol/Contaminants-in-Fuel Diagnosis Fuel: Testing and Inspection Alcohol/Contaminants-in-Fuel Diagnosis Alcohol/Contaminants-in-Fuel Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Test Description Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel injection system and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust or deterioration. Ethanol concentrations of greater than 10 percent in nonblended gasoline or greater than 85 percent with E85 blended gasoline for flexible fuel applications can cause driveability conditions such as hesitation, lack of power, stalling, or no start. Excessive concentrations of ethanol used in vehicles not designed for it may cause fuel system corrosion, deterioration of rubber components, and fuel filter restriction. Reference Information Special Tools J 44175 - Fuel Composition Tester System Verification The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water, as indicated by a water layer at the bottom of the sample, perform the Particulate Contaminants in Fuel Testing Procedure. If alcohol contamination is suspected, perform the Alcohol in Fuel Testing procedure. Alcohol in Fuel Testing with Special Tool 1. Test the fuel composition using J 44175 - Tester and Instruction Manual. 2. If water appears in the fuel sample, clean the fuel system. 3. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in the fuel sample. 4. If the nonblended gasoline fuel sample measures more than 15 percent ethanol, or if the E85 blended gasoline fuel sample measures more than 91 percent ethanol, add fresh regular gasoline to the vehicle's fuel tank. 5. Test the fuel composition. 6. If additional testing indicates that the ethanol percentage is still above 15 percent for a nonblended gasoline sample, drain and replace the vehicle's fuel. Refer to Fuel Tank Draining (See: Fuel Tank/Service and Repair/Procedures). If additional testing indicates that the E85 blended gasoline sample still measures above 91 percent, continue adding fresh, regular gasoline until the ethanol content is 85 percent or less. Alcohol in Fuel Testing without Special Tool 1. Using a 100 ml (3.38 oz) specified cylinder with 1 ml (0.034 oz) graduation marks, fill the cylinder with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid volume to 100 ml (3.38 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. Particulate Contaminants in Fuel Testing Procedure 1. Using an approved fuel container, draw approximately 0.5 liter (0.53 qt) of fuel. Page 5661 Body Control Module (BCM) X2 Page 5917 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 7038 Second Design - Black Painted (DO NOT Lube) Hydraulic Assist Power Steering First Design - Bare Steel Tube (Lube OK) Second Design - Black Painted (DO NOT Lube) In the unlikely event that the source of the noise is identified as a second design shaft with black painted tube, it must be replaced. Correction 1 (Only for First Design - DO NOT USE FOR 2ND DESIGN) Lubricate the intermediate shaft with steering column shaft lubrication kit, P/N 26098237. 1. From inside the vehicle, remove the instrument panel insulator panel - left side panel to gain access to the intermediate shaft. 2. Remove the intermediate shaft to steering column attachment bolt. 3. Remove the intermediate shaft from the steering column. 4. Extend the intermediate shaft all the way. Using the intermediate shaft grease kit, P/N 26098237, inject the grease into the gap between the inner shaft and the outer shaft as you are collapsing the shaft. This will draw the grease into the shaft. 5. Cycle the shaft up and down several times to distribute the grease. Important Remove original thread locker material from the bolt and apply Loctite(R) 242 (or equivalent) to the threads of the bolt and reinstall intermediate shaft bolt. 6. Install the intermediate shaft to the column. Tighten - For electronic power steering, tighten the bolt to 49 Nm (36 lb ft). - For hydraulic power steering, tighten the bolt to 62 Nm (46 lb ft). Page 3866 Torque Converter Clutch Solenoid: Diagrams Component Connector End Views Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve (ME7 or MN5) Page 2105 Coolant Reservoir: Service and Repair Radiator Surge Tank Inlet Hose/Pipe Replacement Radiator Surge Tank Inlet Hose/Pipe Replacement Body - Vehicle Glass Distortion Information Front Door Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 5301 connector housing. Refer to Repairing Connector Terminals in SI. 15. Insert the wire into the new conduit and tape the conduit end at the connector. Tape the conduit closed every 255 mm (10 in) with electrical tape. 16. Connect the fan end electrical connector into the cooling fan. 17. Fasten the new wire and conduit with tie wraps (GM P/N 12337820), as shown below. At the cooling fan end of the wire and conduit, leave adequate slack to allow for engine movement (white tie wraps are used for display purposes, use black tie wraps to match the original appearance). With RPO LY7 - Fasten the new wire and conduit to the existing harness with wire tie wraps as shown. With RPOs LZ9, LZ4 or LZE - Fasten the new wire and conduit to metal the transmission cooler lines as shown. (The lower cover has been removed to show the location of the wire tie wraps.) 18. Trim the wire and conduit to length at the underhood fuse block area. 19. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 20. Strip the wire insulation as required and install the terminal, GM P/N 15324340, on the wire. Refer to Repairing Connector Terminals in SI. 21. Reinstall the terminal into A2 on the junction block. Reinstall the TPA and the harness back cover. 22. Reconnect the harness to the under hood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 23. Reinstall the underhood fuse block into it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. Install the 40-amp fuse, GM P/N 15319478. 24. Reinstall the battery. Refer to Battery Replacement in SI. 25. Reinstall the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 26. Reinstall the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 27. Confirm the high speed cooling fan operation using the Tech 2(R). Parts Information Page 7219 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 5536 Instrument Panel Cluster (IPC) Page 10123 Page 6742 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Locations Sunroof / Moonroof Motor: Locations Passenger Compartment/Roof Component Views Roof/Headliner Components (CF5) 1 - Sunroof Motor (part of the Sunroof Control Module) 2 - Sunroof Control Module Page 7133 7. Wipe off any excessive grease on the intermediate shaft to avoid damage from drips on the carpet. 8. Install the instrument panel insulator panel - left side. 9. Verify that the noise is no longer present. Condition 2 There may be interference between the clamp and the steering gear input shaft. The clamp is beveled and if forced down on the input shaft too hard, it may cause a loose fit with the intermediate shaft to input shaft joint. Correction 2 To correct this condition, perform the following steps: 1. Remove the intermediate shaft pinch bolt at the steering gear end. 2. Install a new bolt, GM P/N 07845238, but do not tighten the bolt at this time. 3. Pry the clamp up using a pry bar to position the bolt into the upper part of the groove as shown above. This will position the clamp off the bevel. 4. While keeping the clamp in the upper position, tighten the bolt. Tighten Tighten the bolt to 49 Nm (36 lb ft). 5. Verify that the clunk noise is no longer present. Condition 3 Important This condition ONLY applies to 2004-2007 Chevrolet Malibu/Maxx and 2005-2007 Pontiac G6. Some customers may comment on a knocking or rattling type noise from the front of the vehicle when driven at low speeds and over bumps. The noise only occurs when the steering wheel is in the straight ahead position and sounds like the noise is in the left suspension of the vehicle or directly in front of the driver. Correction 3 1. Ensure the noise is not caused by Condition # 1. 2. Determine the source of the noise. Install the chassis ears at the following locations: - sway bar link - one side at a time - upper strut mount - one side at a time - steering gear near the pinion area - base of the steering column housing - radiator surge tank 3. If the noise is coming from the upper strut mount or sway bar link, replace as necessary and retest. 4. For 2004-2006 Chevrolet and Pontiac model year vehicles, the noise may be coming from the radiator surge tank area. (The 2007 model year vehicles use a different style radiator surge tank - refer to Step 9.) 5. If the noise is coming from the radiator surge tank, release the two retaining tabs holding the radiator surge tank and reposition the tank away from the attaching bracket and isolate with closed cell foam. 6. Cut three pieces of closed cell foam, P/N P46515 (or equivalent), into 25 mm (1 in) by 102 mm (4 in) pieces. 7. Cut two pieces of closed cell foam into 25 mm (1 in) by 6 mm (1/4 in) pieces. Page 3075 Engine Control Module: Service and Repair Engine Control Module Replacement Removal Procedure Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Disconnect the body wiring harness electrical connector (1) from the engine control module (ECM). Page 7983 3. Disconnect the seat to body harness connector (1). Disconnect the seat airbag connector (2). Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing into the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Slide the conduit away on the seat airbag harness and remove just enough tape on the body harness to access the wires to install the terminals and seals. Note Use caution when stripping insulation. Take care not to cut through the wire strands. 5. Slide the wire seals onto all four leads back enough to enable removal of the insulation. Install the blue seals (1) on the body harness and the white seals (2) on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Page 1122 Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections in order to ensure correct alignment readings: * Inspect for visible damage to the suspension components and replace as necessary. * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label) and Tire Diagnosis - Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear). * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Specifications). * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis). * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Specifications/Mechanical Specifications/Steering/System Specifications). * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle). * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Note: * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear toe adjustment first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Front Camber Adjustment Front Camber Adjustment Electrical - Various Electrical Concerns/False Messages Door Switch: All Technical Service Bulletins Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Page 4961 Electronic Brake Control Module (EBCM) (LY7 or LZ4 or LZE) Locations Transmission Control System Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 6794 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Page 2689 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor (1) from the thermostat housing. Installation Procedure Page 1943 19. Remove the intake manifold lower bolts (1). 20. Remove the intake manifold upper bolt and nuts. 21. Remove the intake manifold. Note: The intake manifold gasket is reusable, only replace the gasket if damage has occurred. 22. Remove and inspect the intake manifold gasket. Installation Procedure Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 120 Page 1938 Intake Manifold: Specifications Intake Manifold to Cylinder Head Bolt ....................................................................................................................................................... 10 Nm (89 lb in) Intake Manifold to Cylinder Head Nut ........................................................................................................................................................ 10 Nm (89 lb in) Intake Manifold to Cylinder Head Stud ......................................................................................................................................................... 6 Nm (53 lb in) Description and Operation Steering Wheel: Description and Operation Steering Wheel and Column Description and Operation The steering wheel and column has 4 primary functions: * Heated Steering Wheel * Vehicle steering * Vehicle security * Driver convenience * Driver safety Heated Steering Wheel The heated steering wheel control module controls the heated steering wheel and the heated steering wheel ON indicator based on an input from the heated steering wheel switch. When the heated steering wheel switch is pressed, the switch signal circuit is pulled to ground. This indicates to the heating steering wheel control module that steering wheel heat is requested. When the request is seen, the heated steering wheel control module supplies ground to the indicator lamp and supplies voltage to the heating elements, which are internal to the steering wheel. The heated steering wheel temperature is monitored through an internal temperature sensor. When the steering wheel reaches operating temperature the module will cycle the voltage on and off to maintain the operating temperature. Vehicle Steering The steering wheel is the first link between the driver and the vehicle. The steering wheel is fastened to a steering shaft within the column. At the lower end of the column, the intermediate shaft connects the column to the steering gear. Vehicle Security, Found on Some Vehicle Models Theft deterrent components are mounted and designed into the steering column. The following components allow the column to be locked in order to minimize theft: * The ignition switch-location varies * The steering column lock-content varies * The ignition cylinder-location varies * The theft deterrent module-location varies Driver Convenience The steering wheel and column may also have driver controls attached for convenience and comfort. The following controls may be mounted on or near the steering wheel or column. * The turn signal switch * The hazard switch * The headlamp dimmer switch * The wiper/washer switch * The horn pad/cruise control switch * The redundant radio/entertainment system controls * The manual/power tilt or tilt/telescoping functions * The power pedal adjustment control switch * The navigation/OnStar(R) features * The HVAC controls Driver Safety The steering wheel and column has safety features to protect the driver. The following components may be mounted on or near the steering column: Energy-Absorbing Steering Column - The energy-absorbing steering column compresses in the event of a front-end collision, which reduces the chance of injury to the driver. The energy-absorbing feature, collapsible steering shaft, and break away mounting features help reduce the injury in the event of an accident. In addition to these features, the following driver safety features may be on the steering column. To inspect the steering column for damage, refer to Steering Column Accident Damage Inspection (See: Steering Column/Testing and Inspection/Initial Inspection and Diagnostic Overview). Electronic Park Lock (EPL)/Ignition Lock Cylinder Control Actuator - If the vehicle is equipped with automatic transmission and a floor mounted console gear shift, it has an ignition lock cylinder control actuator system in the steering column. The ignition lock cylinder control actuator purpose is to prevent the ignition key from being turned to the OFF position when the transmission is in any position other than PARK and the vehicle may still be moving. The column ignition lock system consists Page 6682 Note DO NOT replace the sensing and diagnostic module (SDM), side sensors or air bag modules. Note Both driver and passenger seats must be repaired when this concern occurs even if only one DTC code is set. The service kit contains sufficient components to repair both seat connectors. Connector Replacement Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above includes harness and connector clips, which are not required in this installation. Replace connectors on both driver and passenger seats, and then reposition the connectors following the steps below. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Note Only use hand tools to remove the seat to floor mounting bolts. If there are any problems with bolt removal, refer to Corporate Bulletin Number 10-08-50-002. 2. Remove the driver's seat to floor mounting bolts. Loosen the seat from the front retainers and tilt it back to expose the underside of the seat. Refer to Front Seat Replacement - Bucket in SI. Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 7132 Second Design - Black Painted (DO NOT Lube) Hydraulic Assist Power Steering First Design - Bare Steel Tube (Lube OK) Second Design - Black Painted (DO NOT Lube) In the unlikely event that the source of the noise is identified as a second design shaft with black painted tube, it must be replaced. Correction 1 (Only for First Design - DO NOT USE FOR 2ND DESIGN) Lubricate the intermediate shaft with steering column shaft lubrication kit, P/N 26098237. 1. From inside the vehicle, remove the instrument panel insulator panel - left side panel to gain access to the intermediate shaft. 2. Remove the intermediate shaft to steering column attachment bolt. 3. Remove the intermediate shaft from the steering column. 4. Extend the intermediate shaft all the way. Using the intermediate shaft grease kit, P/N 26098237, inject the grease into the gap between the inner shaft and the outer shaft as you are collapsing the shaft. This will draw the grease into the shaft. 5. Cycle the shaft up and down several times to distribute the grease. Important Remove original thread locker material from the bolt and apply Loctite(R) 242 (or equivalent) to the threads of the bolt and reinstall intermediate shaft bolt. 6. Install the intermediate shaft to the column. Tighten - For electronic power steering, tighten the bolt to 49 Nm (36 lb ft). - For hydraulic power steering, tighten the bolt to 62 Nm (46 lb ft). Page 8373 Garage Door Opener Transmitter: Description and Operation Garage Door Opener Description and Operation The garage door opener (GDO) is fixed and rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the GDO to change every time the GDO is used within operating range of the receiver. Rolling code programming requires the customer to push a learn/program button on the GDO receiver at their home. This button is usually located on the receiver unit under a cover (light cover) on one end of the unit. The customer must follow the GDO manufacturers instructions to program/learn the receiver to accept the Universal Home Remote System as an authorized opener for their unit. When the receiver and the GDO are initially programmed together, a code is established and a new code is created for every new transmission. The software in the receiver recognizes the GDO and accepts the new code. The GDO is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, refer to 1-866-572-2728. The GDO is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of radio frequency interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters. The GDO has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 GDOs, security gates, lighting systems, etc. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Page 1414 Fuse: Application and ID Fuse Block - Rear Electrical Center Identification Views Fuse Block - Rear Label Page 10051 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Specifications Compression Check: Specifications Engine Compression Test The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Page 5588 Starter Generator X3 (KY1) Starter Generator X4 (KY1) Starter Generator Control Module (SGCM) X1 (LAT) Page 3068 Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement Page 2696 Page 1043 1 - Control Valve Body Cover Assembly 2 - Transmission Fluid Level Indicator Assembly 3 - Fluid Level Indicator Tube - Model Dependent 4 - Fluid Level Indicator Tube Seal - Model Dependent 5 Control Valve Body Cover Assembly Gasket 6 - Control Valve Body Cover Stud 7 - Control Valve Body Cover Bolt 8 - Control Valve Body Bolt 9 - Control Valve Body Bolt 10 - Control Valve Body Cover Wiring Connector Hole Seal 11 - Control Solenoid Valve Spring 12 - Control Valve Body Bolt 13 - Control Valve Body Bolt 14 - Control Valve Body Bolt 15 - Control Solenoid (w/Body and TCM) Valve Assembly 16 - Control Solenoid (w/Body and TCM) Filter Plate Assembly 17 - Manual Shaft Detent Assembly 18 - Control Valve Body Assembly 19 - A/Trans Output Speed Sensor Assembly 20 - A/Trans Output Speed Sensor Bolt 21 - A/Trans Case Assembly 22 - Torque Converter Housing Outer Seal 23 - Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly 24 Front Differential Drive Pinion Gear Lube Tube Page 2452 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement Page 6853 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Page 2255 1. Install the exhaust manifold heat shield. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust manifold heat shield bolts and tighten to 10 Nm (89 lb in). 3. Install the bank 2 sensor 1 HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (). Page 5531 Inflatable Restraint Steering Wheel Module X1 Inflatable Restraint Steering Wheel Module X2 Page 7608 7. Remove the thermal expansion valve screws. 8. Remove the thermal expansion valve. 9. Remove and discard the sealing washers. 10. Remove the evaporator. Installation Procedure 1. If replacing the evaporator, add the specific amount of PAG(R) oil directly to the evaporator. Refer to Refrigerant System Specifications (See: Refrigerant/Specifications). Page 5502 Heater Coolant Pump (HP7) Page 5976 Page 3681 2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid valve spring (7) into position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Install all bolts before tightening, then tighten in specified sequence. 4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x 55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6 x 42. 8. Install the 2 control valve body bolts (4) M6 x 65 and tighten to 12 Nm (106 lb in). 9. Connect the input speed sensor electrical connector (1). 10. Connect the output speed sensor electrical connector (2). 11. Connect the shift position switch electrical connector (3). 12. Install the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Transmission and Drivetrain/Automatic Page 3301 2. Connect the EVAP canister line quick connect fitting (2) to the EVAP canister vent solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 3. Connect the fuel tank fuel pump wiring harness electrical connector (1) to the EVAP canister vent solenoid valve. Page 8691 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Bracket Replacement Front Bumper Fascia Bracket Replacement Page 8786 1. Position the outside door handle rod (2) in the clip (1) in order to eliminate any free play in the outside door handle. 2. Install the clip cover closed over the threaded outside door handle rod. 3. Inspect the door lock system for proper operation. 4. Install the rear door water deflector as needed. Refer to Rear Side Door Water Deflector Replacement (See: Rear Door Panel/Service and Repair/Rear Side Door Water Deflector Replacement). 5. Install the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair/Rear Side Door Trim Panel Replacement). Page 3715 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Electronic Components (MH8) Page 5155 Page 3938 Fluid Line/Hose: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Transmission Fluid Cooler Pipe Connector Replacement - Radiator Transmission Fluid Cooler Pipe Connector Replacement - Radiator Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 2. Remove the transaxle oil cooler hoses from the oil cooler fittings on the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection). Note: Do not remove the upper and lower transaxle oil cooler fittings from the radiator at the same time other wise the transaxle oil cooler will fall inside the radiator end tank. 3. Remove the oil cooler fitting from the radiator. Installation Procedure 1. Inspect the new O-ring seals for cracks, cuts or damage. Replace if necessary. Page 7065 Tie Rod: Service and Repair Steering Linkage Outer Tie Rod Replacement Steering Linkage Outer Tie Rod Replacement Page 4689 Lateral Accelerometer: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Battery Negative Cable Replacement Negative: Service and Repair Battery Negative Cable Replacement Battery Negative Cable Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery Negative Cable Disconnection and Connection). 2. Remove the negative cable ground terminal nut at the tie bar. 3. Remove the negative battery cable clip from the battery tray. 4. Remove the tape holding the positive cable to the negative cable. 5. Remove the negative cable from the retainers. 6. Remove the battery cable/ground cable lead nut (2) from the transmission stud. 7. Remove the engine harness and negative battery cable leads. 8. Remove the ground cable. Installation Procedure OnStar(R) - Availability for Hearing Impaired Communications Control Module: Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Service and Repair PCV Valve Hose: Service and Repair Positive Crankcase Ventilation Hose/Pipe/Tube Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Reposition the positive crankcase ventilation (PCV) hose clamp (1) at the camshaft cover. 3. Remove the PCV hose (2) from the camshaft cover. Installation Procedure 1. Install the PCV hose (2) to the camshaft cover. 2. Position the PCV hose clamp (1) at the camshaft cover. 3. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Exhaust Manifold Heat Shield Replacement Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement Exhaust Manifold Heat Shield Replacement Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure Important: If replacing the steering wheel position sensor, the new sensor MUST come with a locating pin installed. If a locating pin is not installed, return and reorder a new steering wheel position sensor. Do not apply force to the steering wheel position sensor in a sideways direction. When reusing the steering wheel position sensor you must install a locating pin before removing it from the steering column. If the steering wheel position sensor loses its correct position it must be discarded. The locating pin diameter must be in the range of 1.0-2.0 mm. 1. Set the front wheels in the straight-ahead position and install anti-rotation pin J 42640 in the steering column lower access hole. 2. Disconnect the intermediate steering shaft from the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering/Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 3. Disconnect any electrical connectors as needed. 4. Remove the steering wheel position sensor. Assembly Procedure Page 10133 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Page 4199 Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 4. Remove the transmission range selector lever nut (1). 5. Remove the transmission range selector lever (2). Installation Procedure Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 1. Install the transmission range selector lever (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission range selector lever nut (1) and tighten to 30 Nm (22 lb ft). Page 9400 Seat Horizontal Motor - Driver (AG1 or LTZ) Seat Horizontal Motor - Passenger (LTZ) Page 6539 X601 Inline Harness Connector End Views X601 Right Front Door Harness to Right Front Door Trim Pad Harness Page 6735 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 9892 Page 9615 Page 5781 Fuse Block - Underhood X3 Page 3199 Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 4. Remove the transaxle range switch lever nut and lever. 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. Page 5480 Generator X2 (LE5 or LE9) Generator X2 (LY7) Generator X2 (LZ4 or LZE) Page 9373 Sunroof / Moonroof Module: Diagrams Component Connector End Views Sunroof Control Module (CF5) Page 4461 2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid valve spring (7) into position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Install all bolts before tightening, then tighten in specified sequence. 4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x 55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6 x 42. 8. Install the 2 control valve body bolts (4) M6 x 65 and tighten to 12 Nm (106 lb in). 9. Connect the input speed sensor electrical connector (1). 10. Connect the output speed sensor electrical connector (2). 11. Connect the shift position switch electrical connector (3). 12. Install the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Page 9198 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 10366 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 2661 Locations Pedal Positioning Sensor: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Lower Left Side of the Instrument Panel Components (1 of 2) Page 10275 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Page 9582 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools Page 7002 Steering Gear: Service and Repair Steering Gear Boot and Breather Tube Replacement - Off Vehicle Steering Gear Boot and Breather Tube Replacement - Off Vehicle Tools Required J 22610 Keystone Clamp Pliers. Disassembly Procedure 1. To remove the outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 2. Remove the hexagon jam nut (2) from the inner tie rod assembly (1). 3. Remove the tie rod end clamp (2) from the rack and pinion boot (1). Page 1434 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a conductive M6 rivet stud and a conductive M6 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new, conductive M6 rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new, conductive M6 rivet stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 16. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). 17. Check for proper system operation. Page 10252 Transmission Mode Indicator - A/T: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Automatic Transmission Control Indicator Replacement Page 5632 Accelerator Pedal Position (APP) Sensor Page 2350 Page 1803 Caution: Installing the metal shaving catch plug deeper than the recommended depth will create a decrease in vacuum system performance. A decrease in vacuum system performance will cause metal shavings to enter the engine and cause engine failure. Caution: Installing the metal shaving catch plug above the recommended depth will cause damage to the metal shaving catch plug. 4. Ensure that the EN 45680-883 metal shaving catch plug is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. Note: Before using EN 45680-881 trim tool assembly, the height of the cutting blades must be set to the proper specification. The proper specification is that the cylinder bore sleeve flange must be flush to +0.02 mm (0.0008 in) above the block deck surface. 5. The groove side of the EN 45680-882 set gauge ring (1) should be positioned upward on a flat surface. Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 5448 Page 5322 Page 1394 Body Control Module (BCM) X4 Page 4326 1. Install the side cover gaskets (5 and 6) into the grooves on the side cover (1). 2. Retain the seals with J 36850 or equivalent. 3. Install the side cover to drive sprocket thrust washer (7) onto the side cover. 4. Retain the thrust washer with J 36850 or equivalent. 5. Install the transmission side cover. Refer to Control Valve Body Cover Replacement (See: Control Valve Body Cover Replacement). Control Valve Body Replacement Control Valve Body Replacement Removal Procedure 1. Remove the transaxle case side cover. Refer to Control Valve Body Cover Replacement (See: Control Valve Body Cover Replacement). 2. Remove the oil pump bolts and the oil pump assembly. 3. Remove the oil pump shaft. Page 4892 10. Disconnect the master cylinder secondary brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination. 11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 12. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 13. Remove the 3 BPMV bracket nuts (1). 14. Remove the BPMV and bracket assembly. Page 6543 X800 Inline Harness Connector End Views X800 Body Harness to Right Rear Door Harness Page 5205 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Locations Sunroof / Moonroof Switch: Locations Passenger Compartment/Roof Component Views Roof/Headliner and Overhead Console Components 1 - Dome/Reading Lamps 2 - Center Console Flood Lamp 3 - Sunshade - Right 4 - Vanity Mirror Lamp - Right (2TL or LTZ) (Part of Sunshade - Right) 5 - Garage Door Opener (GDO) (UG1) 6 Courtesy/Reading Lamps - Right Front 7 - Sunroof Switch (CF5) 8 - Courtesy/Reading Lamps Left Front 9 - Vanity Mirror Lamp - Left (2TL or LTZ) (Part of Sunshade - Left) 10 - Sunshade - Left 11 - Cellular Telephone Microphone (UE1) Diagrams Ignition Control Module: Diagrams Component Connector End Views Ignition Control Module (ICM) (LZ4 or LZE) Page 646 Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor Page 10110 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 3440 10. Install the right rear frame reinforcement (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 11. Install the right rear frame bolts (4) and tighten to 100 Nm (74 lb ft) plus an additional 90 degrees using the J 45059. 12. Lower the vehicle. 13. Install the brake pipes to the clips. 14. Install the brake, fuel, and EVAP pipe clips (1, 2) to the studs on the front of dash. Page 9508 Page 1994 2. Working clockwise around the chain, place the chrome link (4) in line with the timing mark (3) on the balance shaft drive sprocket (approximately 6 o'clock position on the sprocket). 3. Place the chain (7) on the water pump drive sprocket. The alignment is not critical. 4. Align the last chrome link (6) with the timing mark (1) on the exhaust side balance shaft drive sprocket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the upper balance shaft drive chain guide and bolts and tighten to 15 Nm (11 lb ft). 5. Install the small balance shaft drive chain guide and bolts and tighten to 15 Nm (11 lb ft). Page 5399 Camshaft Position (CMP) Sensor - Bank 2 Exhaust (LY7) Page 1026 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). 6. Remove the alignment tool. Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 7. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Page 9425 Seat Back: Service and Repair Rear Seat Back Cushion Support Replacement Rear Seat Back Cushion Support Replacement Locations Rear Shelf: All Technical Service Bulletins Interior - Rear Shelf Foam Seal Is Loose TECHNICAL Bulletin No.: 09-08-110-001A Date: July 23, 2010 Subject: Loose Foam Seal Between Rear Window Shelf Trim Panel and Rear Glass (Replace Foam Seal) Models: 2008-2011 Chevrolet Malibu Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-110-001 (Section 08 - Body and Accessories). Condition Some customers may comment that the foam seal material between the rear window shelf trim panel (parcel shelf) and the rear glass is loose and exposed. Cause The foam anti-rattle seal may have been stretched when it was applied to the trim panel. Heat can cause the foam to shrink and the adhesive to fail, allowing the seal to separate from the trim panel. Correction Important DO NOT replace the rear window shelf trim panel for this condition. Use the following procedure to install a new foam seal. 1. Remove the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel in SI. 2. Remove the foam seal from the trim panel. 3. Clean any adhesive residue from the attaching surface on the trim panel using a general purpose adhesive cleaner. 4. Install a piece of Kent Industries P/N P46495*, 11 mm X 9 mm (3/8 in X 7/16 in) adhesive-backed pressure sensitive sponge rubber weatherstrip material, or the equivalent, on the trim panel in the location of the original foam seal. 5. Clean any adhesive residue from the rear window using a general purpose adhesive cleaner. 6. Reinstall the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel in SI. Adjustments Front Door Exterior Handle: Adjustments Front Side Door Outside Handle Rod Adjustment Page 10616 Page 69 Page 9470 Page 4147 Shift Solenoid: Service and Repair 6T70/6T75 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/6T70/6T75 Automatic Transmission/Control Valve Body Cover Replacement). 2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3). 5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring (8) to the side. Spring will be released with the removal of the control valve body assembly. Page 5220 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Page 8201 Page 1760 Camshaft: Service and Repair Camshaft Position Intake Actuator Replacement Camshaft Position Intake Actuator Replacement Special Tools * EN-45059 - Angle Meter * EN-48749 - Timing Chain Retention Tool Kit * EN-48953 - Camshaft Actuator Locking Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the camshaft cover. Refer to Camshaft Cover Replacement (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 2. Remove the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 3. Rotate the crankshaft clockwise and install the EN-48953 - retention tool (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the camshaft actuator retainer bolts and tighten to 10 Nm (89 lb in) . 5. Loosen, but DO NOT remove the intake camshaft actuator bolt. 6. Remove the EN-48953 - locking tool (1). 7. Clean the timing chain and gears with solvent. Note: Ensure the timing chain and the camshaft position actuators are marked for proper assembly. 8. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain. Page 3525 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position (CKP) system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * CKP sensor replacement * Any engine repairs which disturb the crankshaft to CKP sensor relationship Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the CKP system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensor activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the CKP system variation learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicle's transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 8290 Page 1164 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure Caution: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage. 1. Remove the ignition coil(s). Refer to Ignition Coil Replacement (See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair ). Note: Make sure that any water and/or debris is blown out of the spark plug holes prior to removing the spark plugs. 2. Remove the spark plugs using a 5/8 inch spark plug socket. Installation Procedure Page 5566 Seat Adjuster Switch - Driver (without LTZ and AG1) Page 2483 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the engine oil pressure switch. Tighten the switch to 22 Nm (16 lb ft). 2. Connect the engine wiring harness electrical connector (2) to the oil pressure switch. 3. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). Page 4773 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Page 989 1. Slide the steering wheel position sensor into place and remove the locating pin. 2. Connect any electrical connectors as needed. 3. Connect the intermediate steering shaft to the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 4. Remove anti-rotation pin J 42640. Page 8208 Page 3295 Canister Vent Valve: Harness Locations Harness Routing Views Body Harness Routing - Right Rear Passenger Compartment and Underbody 1 - G301 2 - X412 3 - Evaporative Emission (EVAP) Canister Vent Solenoid Valve 4 - X413 5 X403 Page 1587 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Page 1243 Heater Hose: Service and Repair Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement Page 7536 9. Remove the right front fender liner. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 10. Remove the right radiator air deflector retainers. 11. Remove the right radiator air deflector. 12. Remove the left radiator air deflector retainers. 13. Remove the left radiator air deflector. Page 5026 2. Measure from the same end as earlier, and slide the current sensor to that measurement on the negative battery cable. 3. Install the battery negative cable. Refer to Battery Negative Cable Replacement (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). Page 2472 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 5621 Window Motor - Right Rear Page 8974 Second Design - Black Painted (DO NOT Lube) Hydraulic Assist Power Steering First Design - Bare Steel Tube (Lube OK) Second Design - Black Painted (DO NOT Lube) In the unlikely event that the source of the noise is identified as a second design shaft with black painted tube, it must be replaced. Correction 1 (Only for First Design - DO NOT USE FOR 2ND DESIGN) Lubricate the intermediate shaft with steering column shaft lubrication kit, P/N 26098237. 1. From inside the vehicle, remove the instrument panel insulator panel - left side panel to gain access to the intermediate shaft. 2. Remove the intermediate shaft to steering column attachment bolt. 3. Remove the intermediate shaft from the steering column. 4. Extend the intermediate shaft all the way. Using the intermediate shaft grease kit, P/N 26098237, inject the grease into the gap between the inner shaft and the outer shaft as you are collapsing the shaft. This will draw the grease into the shaft. 5. Cycle the shaft up and down several times to distribute the grease. Important Remove original thread locker material from the bolt and apply Loctite(R) 242 (or equivalent) to the threads of the bolt and reinstall intermediate shaft bolt. 6. Install the intermediate shaft to the column. Tighten - For electronic power steering, tighten the bolt to 49 Nm (36 lb ft). - For hydraulic power steering, tighten the bolt to 62 Nm (46 lb ft). Page 1063 Power Window Switch: Diagrams Component Connector End Views Window Switch - Driver X1 Window Switch - Driver X2 Page 917 1. Lubricate the CKP sensor O-ring seal with clean engine oil. 2. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CKP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 5. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 6. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Page 2800 Page 4260 Warning Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the front transaxle mount through bolt nut (1). 3. Remove the front transaxle mount through bolt (2). 4. Remove the transaxle mount-to-transaxle attachment bolts (2). 5. Remove the transaxle mount (1) from the vehicle. Installation Procedure Page 1032 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Electronic Components (MH8) Page 7245 Frequently Asked Questions Disclaimer Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 2268 Note: Replace the muffler hangers and exhaust gaskets any time the exhaust system is removed from the vehicle. Do not use any mineral oil based lubricants or sharp tools when installing new exhaust system hangers. 1. With the aid of an assistant, position the muffler assembly. 2. Install the muffler insulators to the hangers. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the exhaust pipe to muffler nuts and tighten to 25 Nm (18 lb ft). 4. Lower the vehicle. Page 8935 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Service and Repair Power Steering Pump Seal: Service and Repair Power Steering Pump Shaft Seal Replacement Removal Procedure 1. If necessary, remove the power steering pump. Refer to Power Steering Pump Replacement (See: Service and Repair/Power Steering Pump Replacement). Important: Protect the power steering pump shaft with the shim stock. 2. Use a small chisel in order to remove the power steering pump shaft seal and discard it. Installation Procedure 1. Lubricate the new power steering pump shaft seal using power steering fluid. Page 8364 Digital Video Disc (DVD) Display - Passenger Seat Headrest X1 (SPO Accessory) (UJ5) Page 7320 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 7443 Air Duct: Service and Repair Windshield Defroster Duct Replacement Windshield Defroster Duct Replacement Removal Procedure 1. Remove the instrument panel (I/P) pad. Refer to Instrument Panel Upper Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Upper Trim Panel Replacement). 2. Press on the 2 tabs of the windshield defroster duct. 3. Remove the windshield defroster duct. Installation Procedure 1. Install the windshield defroster duct. Page 5916 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 6150 Body Control Module (BCM) X3 Page 3201 Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 8. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. Page 4133 1 - Control Solenoid Valve Assembly (with Transmission Control Module) Page 3533 Ignition Coil 3 (LAT or LE5 or LE9) Page 9286 Pedal Positioning Module: Diagrams Component Connector End Views Accessory Power Outlet - I/P Accessory Power Outlet - 110V AC (KV1) Locations Variable Valve Timing Solenoid: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) Page 1372 connector housing. Refer to Repairing Connector Terminals in SI. 15. Insert the wire into the new conduit and tape the conduit end at the connector. Tape the conduit closed every 255 mm (10 in) with electrical tape. 16. Connect the fan end electrical connector into the cooling fan. 17. Fasten the new wire and conduit with tie wraps (GM P/N 12337820), as shown below. At the cooling fan end of the wire and conduit, leave adequate slack to allow for engine movement (white tie wraps are used for display purposes, use black tie wraps to match the original appearance). With RPO LY7 - Fasten the new wire and conduit to the existing harness with wire tie wraps as shown. With RPOs LZ9, LZ4 or LZE - Fasten the new wire and conduit to metal the transmission cooler lines as shown. (The lower cover has been removed to show the location of the wire tie wraps.) 18. Trim the wire and conduit to length at the underhood fuse block area. 19. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 20. Strip the wire insulation as required and install the terminal, GM P/N 15324340, on the wire. Refer to Repairing Connector Terminals in SI. 21. Reinstall the terminal into A2 on the junction block. Reinstall the TPA and the harness back cover. 22. Reconnect the harness to the under hood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 23. Reinstall the underhood fuse block into it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. Install the 40-amp fuse, GM P/N 15319478. 24. Reinstall the battery. Refer to Battery Replacement in SI. 25. Reinstall the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 26. Reinstall the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 27. Confirm the high speed cooling fan operation using the Tech 2(R). Parts Information Page 9981 * J-38125-8 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Page 10726 Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 5. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Air Inlet Grille Panel Replacement). 6. Install the windshield wipers arms and blades. Refer to Windshield Wiper Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and Repair). 7. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 8. Close the hood. Windshield Replacement - Brazil Windshield Replacement - Brazil Special Tools * S-0201964 - Bonded, Glass Removing Device * Glass Handling Suction Cups * Use an adhesive that is approved by GM For equivalent regional tools, refer to Special Tools (See: Windows/Tools and Equipment). Removal Procedure Note: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Open the hood. 2. Remove the windshield wiper arms and blades. Refer to Windshield Wiper Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and Repair). 3. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Air Inlet Grille Panel Replacement). 4. Remove the windshield side garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 5. Remove the sunshades. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair/Sunshade Replacement). 6. Remove the inside rearview mirror. Refer to Inside Rearview Mirror Replacement (See: Body and Frame/Mirrors/Service and Repair/Inside Rearview Mirror Replacement). 7. Remove the remote control door lock receiver. Refer to Remote Control Door Lock Receiver Replacement (See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Module/Service and Repair). 8. Lower the front edge of the headliner this will allow the special tool S-0201964 - Bonded, Glass Removing Device to cut across the top of the window and not damage the headliner edge. Warning: Refer to Defroster Outlet Warning (See: Heating and Air Conditioning/Service Precautions). 9. Cover the following parts to protect from broken glass: * Upper dash pad * Defroster outlets and A/C outlets * Seats and carpeting Warning: Refer to Glass and Sheet Metal Handling Warning (See: Body and Frame/Service Precautions/Technician Safety Information/Glass and Sheet Metal Handling Warning). Note: If the original window is being reused the window lace is not serviceable. Page 1860 Page 9150 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Page 492 1 - Brake Pedal Position (BPP) Sensor 2 - Accelerator Pedal Position (APP) Sensor 3 - Accelerator Pedal 4 - Brake Pedal Page 4009 Note: Connect the actuator rod (3) to the detent lever assembly. 1. Install the manual shaft detent (w/shift position switch) lever assembly (4). Note: Lubricate the shaft with automatic transmission fluid to prevent damage to the manual shift shaft seal during installation. 2. Install the manual shaft (2). 3. Install the manual shaft detent lever hub pin (1) using DT-48550. Install the Manual Shaft Detent Lever Hub Pin to height of (b) 7.9 mm (0.38 in). Caution: Use the manual shaft pin installer to install the pin at the correct height in order to properly secure the manual shaft. If you install the pin too deep, the case bore may crack. 4. Install the NEW manual shift shaft pin (5) using J 41229. Use a NEW pin to ensure proper engagement with the case. Inspect pin installed height is within (a) 7.2-8.2 mm (0.28-0.32 in). 6. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See: Testing and Inspection/Programming and Relearning/6T30/6T40/6T45 - Automatic Transmission). Page 5349 Fuse Block - Rear X2 Page 4175 1. Install the shift knob (1) from the shift control. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the shift knob retaining screw (3) and tighten to 4 Nm (35 lb in). 3. Install the boot (2) to the console. Manual Shift Auxiliary Position Switch Replacement - Steering Wheel Manual Shift Auxiliary Position Switch Replacement - Steering Wheel Transmission Control Replacement Transmission Control Replacement Page 161 Page 9937 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview Data Link References This table identifies which serial data link that a particular module uses for in-vehicle data transmission. Some modules may use more than one data link to communicate. Some modules may have multiple communication circuits passing through them without actively communicating on that data link. This table is used to assist in correcting a communication malfunction. For the description and operation of these serial data communication circuits, refer to Data Link Communications Description and Operation (See: Description and Operation). Page 9942 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 6481 Automatic Transmission Output Shaft Speed (OSS) Sensor (ME7 or MN5) Automatic Transmission Shift Lever Position Indicator Locations Torque Converter Clutch Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 3055 Engine Control Module (ECM) X1 (LE5 or LE9) Page 4797 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Brake Rotor Assembled Lateral Runout Measurement Brake Rotor Assembled Lateral Runout Measurement Special Tools * CH-39544-KIT - Complete Torque Socket Set - 10 PCS, or equivalent * CH-41013 - Rotor Resurfacing Kit * CH-42450-A - Wheel Hub Resurfacing Kit * CH-45101 - Hub and Wheel Runout Gauge * CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). 1. Matchmarks the position of the brake rotor to the wheel studs if this has not been done already. Note: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles, corrosion, rust, or debris remaining. If the wheel hub/axle flange and/or if the brake rotor mating surfaces exhibit these conditions, perform the following steps: 1. Remove the brake rotor from the vehicle. Refer to Front Brake Rotor Replacement (See: Service and Repair/Removal and Replacement/Front Brake Rotor Replacement) and/or Rear Brake Rotor Replacement (See: Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 2. Using the CH-42450-A - wheel hub resurfacing kit, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 3. Using the CH-41013 - rotor resurfacing kit, thoroughly clean any rust or corrosion from the mating surface of the brake rotor. 4. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Install the rotor to the hub/axle flange using the matchmarks made prior to removal. Engine Mount Bracket Replacement Engine Mount: Service and Repair Engine Mount Bracket Replacement Engine Mount Bracket Replacement Removal Procedure 1. Remove the engine mount. Refer to Engine Mount Replacement (See: Engine Mount Replacement). 2. Remove the engine mount bracket to engine bolts (1). 3. Remove the engine mount bracket (2). Installation Procedure 1. Position the engine mount bracket (2) to the engine. 2. Install the engine mount bracket bolts (1) in the following locations: Page 5513 Ignition Coil 2 (LY7) Page 3568 Camshaft Position (CMP) Sensor - Intake (LAT or LE5 or LE9) Page 5755 Fuse Block - Rear Top View Page 1256 Note: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur. 8. Install the right radiator air deflector. 9. Install the right radiator air deflector retainers. 10. Install the right front fender liner. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 11. Lower the vehicle. 12. Install the suction hose and liquid line to the TXV. 13. Install the suction hose and liquid line nut to the TXV and tighten to 20 Nm (15 lb ft). 14. Install the liquid line to the dash clip. 15. Install the suction hose to the dash clip. 16. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Filters/Air Cleaner Housing/Service and Repair). Page 464 Page 5838 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Locations Fog/Driving Lamp Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 7175 8. Install the three pieces of foam to the attaching bracket starting at the top center inside the bracket and proceed down across the fuel lines, then at the inside of the bracket at the left and right positions of the center piece of foam. Finally, install the last two pieces of foam to the inside bracket at the left and right extended sides behind the retaining holes as shown above. 9. Reposition the radiator surge tank back onto the bracket and seat the two retaining tabs on the tank. 10. Drive the vehicle to verify that the noise is no longer present. Parts Information Order Adhesive Back Shim Stock from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6203 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 7980 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. Page 3316 Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 9919 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Page 1373 * Use TXL type wire Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 3494 Throttle Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Locations Hazard Warning Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 2906 Page 7085 Ball Joint: Testing and Inspection Ball Joint Inspection Special Tools J 8001 Dial Indicator Set 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Clean and inspect the ball joint seal for cuts or tears. If the ball joint seal is damaged, replace the lower control arm. Refer to Lower Control Arm Replacement (See: Control Arm/Service and Repair/Front Suspension). 3. Install the J 8001 or suitable dial indicator in a way to measure vertical lash in the ball joint. Caution: Do not pry in such a way that the ball joint seal is contacted. Damage to the seal may result. 4. Gently lift or pry the suspension to induce ball joint movement. 5. If the dial indicator indicates a reading greater than 0.5 mm (0.02 in), replace the lower control arm. Refer to Lower Control Arm Replacement ( See: Control Arm/Service and Repair/Front Suspension). Page 5585 Speaker - Right Rear (UQA) Speaker - Right Rear (UQ3) Page 9616 Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 10491 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 1562 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Page 4032 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 4105 Transmission Speed Sensor: Connector Views Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Output Shaft Speed (OSS) Sensor (MH2 or MH8) Page 7434 Page 10613 Window Switch - Left Rear Page 7917 Note DO NOT replace the sensing and diagnostic module (SDM), side sensors or air bag modules. Note Both driver and passenger seats must be repaired when this concern occurs even if only one DTC code is set. The service kit contains sufficient components to repair both seat connectors. Connector Replacement Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above includes harness and connector clips, which are not required in this installation. Replace connectors on both driver and passenger seats, and then reposition the connectors following the steps below. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Note Only use hand tools to remove the seat to floor mounting bolts. If there are any problems with bolt removal, refer to Corporate Bulletin Number 10-08-50-002. 2. Remove the driver's seat to floor mounting bolts. Loosen the seat from the front retainers and tilt it back to expose the underside of the seat. Refer to Front Seat Replacement - Bucket in SI. Page 835 Manifold Absolute Pressure (MAP) Sensor (LZ4 or LZE) Page 7537 14. Remove the liquid line and compressor hose bolt from condenser. 15. Remove the compressor hose from the condenser. 16. Remove the liquid line from the condenser. 17. Remove both lower radiator mounting bracket bolts. 18. Remove both lower radiator mounting brackets. Page 3648 Torque Converter Clutch Solenoid: Diagrams Component Connector End Views Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve (ME7 or MN5) Page 8816 Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement Rear Door Opening Weatherstrip Replacement Page 10006 Page 9790 Seat Adjuster Switch - Driver (without LTZ and AG1) Generator Bracket Replacement Alternator: Service and Repair Generator Bracket Replacement Generator Bracket Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Rotate the drive belt tensioner counterclockwise. 3. Remove the accessory drive belt. Refer to Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 4. Remove the generator. Refer to Generator Replacement (See: Generator Replacement). 5. Remove the drive belt tensioner bolt. Page 7300 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4 in) should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Page 7943 3. Disconnect the seat to body harness connector (1). Disconnect the seat airbag connector (2). Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing into the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Slide the conduit away on the seat airbag harness and remove just enough tape on the body harness to access the wires to install the terminals and seals. Note Use caution when stripping insulation. Take care not to cut through the wire strands. 5. Slide the wire seals onto all four leads back enough to enable removal of the insulation. Install the blue seals (1) on the body harness and the white seals (2) on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Page 8215 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Page 7799 Disclaimer Service Procedure Service Procedure Air Bag Connector Inspection 1. Move the driver's seat to the maximum forward position and raise the seat to its maximum height. 2. Using a flash light, locate the air bag and body wire harnesses. Note Vehicles that have new air bag connectors will have a tie strap securing the two (2) wires exiting the air bag connector to the main body wiring harness. In addition, the new air bag connectors will have an orange connector position assurance (CPA) clip that is tethered to the connector. Ensure both the orange CPA clip and tie strap are located. Air bag and body wire harnesses without the tie strap and/or CPA clip must have the air bag connectors replaced. 3. Determine if the new air bag connectors have been installed. - If the vehicle is equipped with the new air bag connectors, no further action is required. Refer to Warranty Transaction Information in this bulletin. - If the vehicle is NOT equipped with the new air bag connectors, replace the air bag connectors. Refer to Replace Wire Harness Connector in this bulletin. Replace Wire Harness Connector Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. (Seat shown out-of-vehicles for illustration purposes) Page 5648 Automatic Transmission Input Shaft Speed (ISS) Sensor Page 1703 1. Install the wheel bearing/hub assembly to the knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 wheel bearing/hub assembly nuts. Tighten the nuts to 63 Nm (47 lb ft). 3. Install the stabilizer link bolt at the knuckle. Refer to Stabilizer Shaft Replacement (See: Steering and Suspension/Suspension/Stabilizer Bar/Service and Repair/Rear Suspension). 4. Connect the electrical connector to the wheel speed sensor. 5. Install the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 7. Lower the vehicle. Symptoms - Power Outlets Auxiliary Power Outlet: Testing and Inspection Symptoms - Power Outlets Symptoms - Power Outlets Visual/Physical Inspection * Inspect for aftermarket devices which can affect the operation of the power outlets. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories) * Inspect the accessible system components or the visible system components for obvious damage or for obvious conditions which can cause the symptom. Intermittent Electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) Symptom List Refer to Power Outlet Receptacle Malfunction (See: Power Outlet Receptacle Malfunction) in order to diagnose the system. Page 3113 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. (Intake CMP shown, exhaust CMP similar). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect engine wiring harness electrical connector (5) to the exhaust CMP sensor (4). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 6008 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 3513 Camshaft Position (CMP) Sensor - Intake (LAT or LE5 or LE9) Page 6861 Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor (NVH) Page 3541 Refer to Ignition System Specifications (See: Specifications) and Spark Plug Inspection (See: Spark Plug/Testing and Inspection). Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the affected ignition coil/modules. 2. Ignition OFF for 90 seconds, test for less than 5 ohms between the ground circuit terminal A and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Test for less than 5 ohms between the low reference circuit terminal B and ground. ‹› If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the ECM. Important: If the ignition voltage fuse is open, it will be necessary to test the spliced ignition circuits and the components for a short to ground. 4. Ignition ON, verify that a test lamp illuminates between the ignition voltage circuit terminal D and ground. ‹› If the test lamp does not illuminate, test the ignition voltage circuit for a short to ground or an open/high resistance. 5. Exchange the affected ignition coil/module with the ignition coil/module of a good cylinder. 6. Start the engine, and observe the scan tool Misfire Current Cylinder parameters. ‹› If the misfire transfers with the suspect ignition coil/module, replace as needed. 7. If the circuits test normal, test or replace the spark plug/s. Component Testing Use the J 26792 to verify the output of each ignition coil/module. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Ignition Coil Replacement (See: Service and Repair) * Spark Plug Replacement (See: Spark Plug/Service and Repair) Page 8770 Front Door Window Glass: Service and Repair Front Side Door Window Replacement Page 7589 2. Install the lower air temperature sensor. 3. Install the right front floor console extension panel. Refer to Front Floor Console Extension Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Extension Panel Replacement - Right Side). Page 6745 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Front Bumper Fascia Outer Bracket Replacement Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Outer Bracket Replacement Front Bumper Fascia Outer Bracket Replacement Page 10587 1 - Outside Rearview Mirror - Passenger 2 - Door Frame 3 - Door Latch - Passenger 4 - Inflatable Restraint Side Impact Sensor (SIS) - Right 5 - Window Switch - Passenger 6 - Speaker - Right Front 7 - Window Motor - Passenger 8 - Door Lock Switch - Passenger 9 - Courtesy Lamp - Right Front Door Rear Door Components Page 1941 9. Reposition the vacuum brake booster hose clamp (1) at the intake manifold. 10. Remove the vacuum brake booster hose (2) from the intake manifold. 11. Remove the throttle body. Refer to Throttle Body Assembly Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Removal and Replacement). 12. Disconnect the engine wiring harness electrical connector from the manifold absolute pressure (MAP) sensor. 13. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 14. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement (See: Engine Lubrication/Engine Oil Dip Stick - Dip Stick Tube/Service and Repair). 15. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Rail/Service and Repair). Page 5987 Page 4515 Input Speed Sensor Seal Replacement Page 1534 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Testing and Inspection). Page 8810 1. Install the striker (2) to the door opening. Align the striker to the alignment marks. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the screws to the striker. Tighten the screws to 20 Nm (15 lb ft). 3. Adjust door striker. Refer to Door Lock Striker Adjustment (See: Front Door/Front Door Striker/Adjustments). 4. Inspect the door for proper operation. 5. Install the front or the rear trim if removed. 6. Install the body lock pillar lower trim. Refer to Body Lock Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Lower Trim Panel Replacement). 7. Install the lower center pillar trim. Page 7107 1 - Steering Wheel Position Sensor (NVH) 4T45-E - Automatic Transmission Transmission Mode Indicator - A/T: Service and Repair 4T45-E - Automatic Transmission Automatic Transmission Control Indicator Replacement Page 6157 Page 3283 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 3405 4. Install the retainer to the quick connect fitting. Page 6783 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 833 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 1992 20. Remove the small balance shaft drive chain guide bolts and guide. 21. Remove the upper balance shaft drive chain guide bolts and guide. Service and Repair Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Caster Description Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Front Suspension Wheel Bearing: Service and Repair Front Suspension Front Wheel Bearing and Hub Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 3. Disconnect the wheel speed sensor electrical connector, if equipped. 4. Remove the wheel speed sensor electrical connector from the mounting bracket, if needed. 5. Loosen the wheel drive shaft from the wheel bearing/hub. Refer to Wheel Drive Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement). Page 5138 Page 5677 X109 Inline Harness Connector End Views X109 Forward Lamp Harness to Left Headlamp Harness Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Body - Vehicle Glass Distortion Information Windshield: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 8366 Page 4398 6. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race. 7. Hold the inner race 90 degrees to centerline of cage with the lands of the inner race (1) aligned with the windows of the cage (2) and insert the inner race into the cage. 8. Hold the cage and the inner race 90 degrees to centerline of the outer race (1) and align the cage windows (3) with the lands of the outer race. Note: Be sure that the retaining ring side of the inner race faces the halfshaft bar. 9. Place the cage and the inner race into the outer race. 10. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball. 11. Repeat this process until all 6 balls are in place. 12. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease. Page 1583 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Page 6068 GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The Locations Fluid Pressure Sensor/Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 4293 85 - Transaxle Oil Filter Assembly 86 - Oil Level Control Valve 87 - Transaxle Bottom Pan Gasket 88 - Transaxle Oil Pan 89 - Chip Collector Magnet 120 - Chip Collector Magnet (Some Models) 126 - Side Cover Stud 127 - Transmission Wiring Harness Assembly (Some Models) 128 - Electrical Connector Retaining Bracket (Some Models) Case and Associated Parts - L4 Hybrid 1 - Side Cover (Structural) 2 - Axle Oil Seal 3 - Side Cover Bolt 4 - Side Cover Stud 5 - Side Cover Gasket 6 - Side Cover Oil Level Control Gasket 7 - Thrust Washer (Side Cover to Driven Sprocket) 8 - Oil Pump Bolt 9 - Oil Pump Bolt 10 - Transaxle Oil Pump Assembly 11 - Transaxle Wiring Assembly 12 - TFP Manual Valve Position Switch Assembly Bolt 13 - TFP Manual Valve Position Switch Assembly 15 - Wiring Harness Bracket Bolt/Input Speed Sensor Bolt 51 - Transaxle Case 52 - Vent Cap 55 - Torque Converter Assembly 61 - Output Speed Sensor Stud 62 - Output Shaft Speed Sensor 63 - O-Ring Seal (Output Speed Sensor) Page 4253 4. Install the transmission mount (2). 5. Install the transmission mount to transmission bolts (1) and tighten to 90 Nm (66 lb ft). 6. Install the transmission mount to bracket through bolt (1) and tighten to 90 Nm (66 lb ft). 7. Remove the jack stand. 8. Install the left tire and wheel. 9. Lower the vehicle. Transmission Front Mount Replacement Transmission Front Mount Replacement Service and Repair Sunroof / Moonroof Windguard: Service and Repair Sunroof Air Deflector Replacement Removal Procedure 1. Remove the sunroof window. Refer to Sunroof Window Replacement (See: Sunroof / Moonroof Panel/Service and Repair). 2. Power sunroof tracks to the fully rear position. 3. Remove the actuators (2) at the front of each window track. 4. Remove the screws (1) from the sunroof air deflector. 5. Remove the sunroof air deflector from the sunroof module (2). Slide the air deflector rearward until it fully releases from the module. Installation Procedure Front Side Door Outside Handle Housing Replacement Front Door Exterior Handle: Service and Repair Front Side Door Outside Handle Housing Replacement Front Side Door Outside Handle Housing Replacement Page 1859 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Page 3618 2. Attach the ball-sockets to the control assembly body and the shift-lock control lever. 3. Connect the electrical connector to the Shift Lock Control Solenoid. 4. Install the automatic transaxle control assembly. Page 2186 1. Install the thermostat (2) with a NEW thermostat gasket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the thermostat housing bolts (1) and tighten to 10 Nm (89 lb in). 3. Install the surge tank outlet hose. 4. Install the heater inlet and outlet hoses. 5. Install the radiator outlet hose to the thermostat housing. 6. Fill the cooling system. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). Page 7259 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Page 2632 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). 2. Ensure that the location measurement of the battery current sensor was recorded for reference during installation. 3. Squeeze the ground ends of the negative battery cable together and remove the sensor (1) from the cable. Installation Procedure Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 1. Install the battery current sensor (1) by passing the ground ends of the negative battery cable through the sensor. Page 5564 Repeater Lamp - Right Front Se - St Page 7198 When lifting the vehicle with a frame-contact lift, place the front lift pads on the front lower brackets, inboard of the rocker pinch weld flange and outboard of the front frame rail, at the torque box location, as shown. Rear Lift Pads When lifting the vehicle with a frame-contact lift, place the rear lift pads on the rear frame rail, at the torque box location, as shown. Vehicle Jacking Caution: When you are jacking the vehicle at the front locations, be certain that the jack or the jack lift pad does not contact the front fascia, front fascia air dam, or the front fenders. If such contact occurs, vehicle damage may result. When jacking at selected front locations additional clearance may be required for the jacking points. Note: When you are lifting a vehicle with a service jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Front of Vehicle When using a service jack under the front of the vehicle use one of the following locations: * Place the service jack pad in the same location as shown for the front lift pads. * Under the front frame crossmember, as shown. Rear of Vehicle Note: Place jackstands ONLY under strong and stable vehicle structures. When using a service jack under the rear of the vehicle place the jack pad on the rocker panel flange, at the torque box location, as shown. Page 10036 Page 10790 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Page 6272 Engine Control Module (ECM) X1 (LZ4 or LZE) Page 201 Page 7827 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 629 Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If reinstalling the original sensor, or if installing a NEW sensor without a sealer, coat the threads with sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor (1) to the thermostat housing and tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 4662 Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) (LAT) Page 7967 Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information 1. Submit a transaction using the table below. * The amount identified in the Net Item column should represent the actual cost of the woven polyester electrical tape, required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a customer satisfaction program that affects your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle. Page 9491 Page 7800 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Page 9583 * J-38125-8 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Page 159 Page 1273 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement Power Steering Gear Inlet Pipe/Hose Replacement Special Tools J 44586 Power Steering Gear Oil Seal Remover/Installer Removal Procedure 1. Remove the power steering pump pulley. Refer to Power Steering Pump Pulley Replacement (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering Pump Pulley Replacement). 2. Remove the drive belt idler pulley. Refer to Drive Belt Idler Pulley Replacement (). 3. Hoist the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 4. Remove as much power steering fluid from the power steering fluid reservoir as possible. 5. Place drain pans under the vehicle as needed. 6. Remove the 3 engine lift bracket bolts (1) and engine lift bracket (2). Page 3791 4. Remove the shift lock control solenoid. Installation Procedure 1. Route the shift lock control solenoid through the opening in the front of the control assembly. Electrical - Various Electrical Concerns/False Messages Door Switch: All Technical Service Bulletins Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Page 4881 1. Remove the caps or plugs from the opening in the brake caliper and the brake hose. Note: Install NEW copper brake hose gaskets. 2. Assemble the NEW copper brake hose gaskets (2), and the brake hose bolt (1), to the brake hose (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the brake hose-to-brake caliper bolt to the brake caliper and tighten the bolt to 50 Nm (37 lb ft). 4. Install the brake hose to the strut with the brake hose nut (4) and tighten the nut to 14 Nm (124 lb in). 5. Remove the caps or plugs from the brake pipe fitting end and the brake hose end. 6. Install the brake hose to the brake hose body bracket. 7. Install the brake hose retainer (2) over the anti-rotation tabs of the brake hose (3). 8. Connect the brake pipe fitting (1) to the brake hose (3). 9. Use a backup wrench on the brake hose (3). 10. Tighten the brake pipe fitting to 20 Nm (15 lb ft). Page 5452 Page 6495 Page 6005 Page 10069 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Bosch Connectors Bosch Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 3635 4-3 Shift Solenoid (SS) Valve (ME7 or MN5) Control Solenoid Valve Assembly (MH2) Page 10759 Washer Fluid Level Switch: Service and Repair Windshield Washer Solvent Level Indicator Replacement Removal Procedure 1. Remove the front wheelhouse panel splash shield. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 2. Disconnect the washer solvent container level sensor electrical connector. 3. Using a small flat-bladed tool, remove the washer solvent level indicator (4) from the washer solvent container (1). 4. Contain all lost windshield washer solvent into a suitable clean container. 5. Using a small flat-bladed tool, remove the level indicator seal (3) from the washer solvent container (1). Installation Procedure Page 3325 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 1292 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement - Radiator Outlet Pipe to Engine Coolant Thermostat Housing Pipe Radiator Outlet Hose Replacement - Radiator Outlet Pipe to Engine Coolant Thermostat Housing Pipe Page 6714 Disclaimer Page 4982 Note: Ensure the gasket on the outside barrel of the master cylinder is positioned properly and is free of cuts and tears. 4. Install the brake master cylinder to the booster assembly. Refer to Master Cylinder Replacement (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement). Page 9287 Accessory Power Outlet - Center Console Page 340 Page 1449 Page 7331 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 5445 Engine Control Module (ECM) X2 (LAT) Page 1163 * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Page 5408 Crankshaft Position (CKP) Sensor (LAT or LE5 or LE9) Page 6230 Camshaft Position (CMP) Sensor - Exhaust (LAT or LE5 or LE9) Page 7884 Inflatable Restraint Side Impact Sensor (SIS) - Right Page 855 Page 6268 Engine Control Module (ECM) X1 (LE5 or LE9) Page 3565 Camshaft Position (CMP) Sensor - Bank 2 Exhaust (LY7) Page 5681 X181 Inline Harness Connector End Views X181 Right Repeater Lamp Harness to Forward Lamp Harness X206 Inline Harness Connector End Views X206 I/P Harness to Body Harness Page 2728 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 853 Heated Oxygen Sensor (HO2S) 1 (LAT or LE5 or LE9 with MN5) Heated Oxygen Sensor (HO2S) 1 (LE5 or LE9 with MH8) Page 6177 Page 9682 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors Tyco/AMP Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 7513 3. Lower the vehicle. Page 6746 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 9697 If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the Locations Camshaft Position Sensor: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch Page 5782 Page 2917 Information Bus: Symptom Related Diagnostic Procedures Symptoms - Data Communications Symptoms - Data Communications Important: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) before using the symptom tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data links. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to: * Body Control System Description and Operation (See: Body and Frame/Body Control Systems/Description and Operation) * Data Link Communications Description and Operation (See: Description and Operation) Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the systems. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: * Scan Tool Does Not Power Up (See: Scan Tool Does Not Power Up) * Scan Tool Does Not Communicate with High Speed GMLAN Device (See: Scan Tool Does Not Communicate with High Speed GMLAN Device) * Scan Tool Does Not Communicate with Low Speed GMLAN Device (See: Scan Tool Does Not Communicate with Low Speed GMLAN Device ) Scan Tool Does Not Communicate with High Speed GMLAN Device Scan Tool Does Not Communicate with High Speed GMLAN Device Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Page 281 Page 10571 Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Page 9631 Page 1382 FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. ......................................... Passenger Seat Controls Fuse 2 ............................................................... ................................................................................................................................. Driver Seat Controls Fuse 3 ................................................................................................................................... ............................................................................... Not Used Fuse 4 .................................................. .............................................................................................................................................................. .. Not Used Fuse 5 ............................................................................................................................... ......................................... Emission 2, Canister Vent Solenoid Page 6092 To help avoid personal injury, always treat the accessory power receptacle, accessory DC/AC power inverter module, AC circuit wires, and connectors as if AC high-voltage is present. 1. Ignition OFF, test for 12.0-15.0 V across the battery terminals. ‹› If no within the specified range, refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). 2. Ignition ON, connect an AC power extension cord to the X81 accessory power receptacle - 110 V AC. Inserting the extension cord plug into the X81 accessory power receptacle - 110 V AC turns the T1 accessory DC/AC power inverter module ON. 3. Verify the receptacle indicator light comes on. 4. Test for 110-120 V between the terminals at the extension cord. 5. Test for 59-61 Hz AC across the line A and line B terminals of the extension cord. Circuit/System Testing 1. Ignition OFF, disconnect the harness connectors at the T1 Accessory DC/AC power inverter module. 2. Test for less than 10 ohm between the ground circuit terminal 1 X2 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Verify that a test lamp illuminates between the B+ circuit terminal 2 X2 and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 4. Ignition ON, test for less than 1.0 V between the AC circuit terminals listed below and ground: * Terminal 4 X1 * Terminal 6 X1 ‹› If greater than the specified range, test the AC circuit for a short to voltage. 5. Ignition OFF, test for infinite resistance between the AC circuit terminals listed below and ground: * Terminal 4 X1 * Terminal 6 X1 ‹› If less than the specified value, test the AC circuit for a short to ground. 6. Disconnect the harness connector at the X81 accessory power receptacle - 110 V AC. 7. Ignition ON, verify a test lamp illuminates between the control circuit terminal 4 and ground. ‹› If the test lamp does not illuminate, test the control circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the K9 BCM. 8. Verify a test lamp does not illuminate between the signal terminal 1 and ground. ‹› If the test lamp illuminates, test the signal circuit for a short to voltage. If the circuit tests normal, replace the T1 Accessory DC/AC power inverter module. 9. Connect a 3 A fused jumper between the control terminal 4 and the signal terminal 1. 10. Ignition ON, verify that a test lamp illuminates between the T1 Accessory DC/AC power inverter module signal circuit terminal 2 X1 and ground. ‹› If the test lamp does not illuminate, test the signal circuit for a short to ground or an open/high resistance. 11. Ignition OFF, connect the harness connectors at the T1 Accessory DC/AC power inverter module. Ignition ON, test for 110-120 V AC between the X81 accessory power receptacle - 110 V AC terminal 3 and 6. ‹› If not within the specified range, check both AC circuits for an open/high resistance. If all circuits test normal, replace the T1 Accessory DC/AC power inverter module. 12. If all circuits test normal, replace the X81 accessory power receptacle - 110 V AC. Component Testing Page 160 Page 4945 17. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 18. Disconnect the brake pedal position sensor electrical connector. 19. Remove the 2 brake pedal assembly nuts. 20. Remove the brake pedal pushrod retainer clip (1). 21. Remove the wave washers (2) and disconnect the brake pedal pushrod (3) from the pedal pivot pin (4). 22. Tilt the vacuum brake booster upward slightly and remove the booster from the vehicle. Do not apply excessive side pressure on the pushrod. Installation Procedure Driver Seat Cushion Heater Replacement Seat Heater: Service and Repair Driver Seat Cushion Heater Replacement Driver Seat Cushion Heater Replacement A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 2802 Locations Variable Induction Control Valve: Locations Powertrain Component Views Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust Instruments - IPC Odometer Programming Reference Guide Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Page 1963 2. Install the valve spring (3) and retainer (2). 3. Compress the valve spring using the valve spring compressor. 4. Install the valve spring keepers (1). 5. Disconnect the air hose and air hose adapter. 6. Remove the EN-43649 - compressor and EN-43649-10 - adaptor set from the cylinder head. 7. Install the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). Page 5567 Seat Adjuster Switch - Passenger (LTZ) Seat Belt Anchor Pretensioner - Driver Page 3144 Page 10245 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Page 10058 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Page 1608 13. Use the tire changer in order to install the tire to the wheel. Warning To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Page 6430 Tail/Stop and Turn Signal Lamp - Right (without LTZ) Page 781 Camshaft Position (CMP) Sensor - Exhaust (LAT or LE5 or LE9) Page 4786 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Correction Plates Brake Rotor Assembled Lateral Runout Correction - Correction Plates Special Tools * CH-39544-KIT - Complete Torque Socket Set - 10 PCS, or equivalent * CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor assembled LRO measurement procedure, to face upward. 2. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Select the correction plate, following the manufacturer's instructions, which has a specification closest to the assembled LRO measurement. For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm (0.003 in) correction plate would be used. If the Locations Oil Pressure Sender: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) Page 3174 1 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 Front and Right Side of the Engine Components (LY7) Page 1184 Steering Gear Boot Replacement Steering Gear: Service and Repair Steering Gear Boot Replacement Steering Gear Boot Replacement Tools Required J 22610 Keystone Clamp Pliers Removal Procedure 1. Remove the rack and pinion outer tie rod end. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). Important: Mark the location of the steering gear inner tie rod nut before removing it from the steering gear inner tie rod. 2. Remove the steering gear inner tie rod nut and discard it. 3. Remove the outer steering gear boot clamp. 4. Remove the inner steering gear boot clamp and discard it. 5. Disengage and remove the steering gear boot from the steering gear. 6. Inspect the sealing surfaces and threaded shaft portion of the steering gear and the steering gear inner tie rod. The surfaces must be clean and free of any debris. Installation Procedure 1. Install a new clamp loosely on the inner part of the steering gear boot. Page 9169 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 6006 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Page 8218 Page 1336 Refrigerant: Fluid Type Specifications Refrigerant ........................................................................................................................................... ....................................................................... R-134a Page 115 Seat Heater Control Module: Diagrams Component Connector End Views Heated Seat Control Module - Driver X1 (KA1) Heated Seat Control Module - Driver X2 (KA1) Page 2304 Page 9205 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools 6T30/6T40/6T45 - Automatic Transmission Transmission Speed Sensor: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Output Speed Sensor Replacement Output Speed Sensor Replacement Input Speed Sensor Replacement Input Speed Sensor Replacement Removal Procedure 1. Remove the transmission control valve body cover. Page 10793 Wiper Blade: Removal and Replacement Windshield Wiper Blade Replacement Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Service and Repair Hood Hinge: Service and Repair Hood Hinge Replacement Page 8292 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools Service and Repair Vacuum Brake Booster: Service and Repair Power Vacuum Brake Booster Replacement Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Without draining the cooling system or disconnecting the hoses, remove and position aside the radiator surge tank. Refer to Radiator Surge Tank Replacement (See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Radiator Surge Tank Replacement). 3. Clean the brake pressure modulator valve (BPMV) pipe fitting areas of any accumulated dirt and foreign material. 4. Disconnect the electrical connector from the electronic brake control module (EBCM). 5. Place a shop towel under the BPMV to catch any brake fluid loss. 6. Disconnect the RF brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Service and Repair Evaporative Emissions Hose: Service and Repair Evaporative Emission Line Replacement - Chassis Special Tools J 45059 Angle Meter Removal Procedure 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 3. Remove the fuel feed line retainer (1) from the fuel line bracket. 4. Disconnect the fuel feed line quick connect fitting (3) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 5. Disconnect the evaporative emission (EVAP) line quick connect fitting (2) from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 6. Cap the fuel rail pipe and the EVAP purge solenoid in order to prevent possible fuel and/or EVAP system contamination. Page 1111 Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Page 4835 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the 2 brake caliper guide pin bolts and tighten to 35 Nm (26 lb ft). 9. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 10. Lower the vehicle. 11. Fill the master cylinder to the proper level. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 12. Pump the brake pedal 2-3 times in order to seat the rear disc brake pads to the rotor. Front Brake Caliper Bracket Replacement Front Brake Caliper Bracket Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 7358 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 4318 Valve Body: Locations 6T70/6T75 - Automatic Transmission Ball Check Valve Locations Campaign - Service Air Bag Message, Replace Connectors Technical Service Bulletin # 11034 Date: 110314 Campaign - Service Air Bag Message, Replace Connectors CUSTOMER SATISFACTION Bulletin No.: 11034 Date: March 14, 2011 Subject: 11034 - Service Air Bag Message - Replace Connectors Models: 2010 Chevrolet Malibu 2010 Pontiac G6 Some, but not all, of the vehicles involved in this Program were also involved in Customer Satisfaction Program (CSP) 10085. These vehicles are to be inspected to determine if the repair for CSP 10085 included the replacement of the two connectors. If the connectors were replaced, no further action is required on these vehicles. If they were not replaced, dealers are to install the new connectors. Condition Certain 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may have a condition in which wear could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact airbag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG system warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG system DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Some of these vehicles were previously repaired under Customer Satisfaction Program 10085. These vehicles had the wire harness secured, and in some cases, rerouted. They did not require the installation of the two connectors. However, there have been reports of the SERVICE AIR BAG message illuminating in the Driver Information Center after the repair, due to movement of the connector between the body main wiring harness and the front driver and passenger side impact air bag. With this Customer Satisfaction Program, dealers will install the two new connectors. Correction Dealers are to inspect and, if necessary, replace the front seat-mounted side impact air bag connectors. Vehicles Involved Involved are certain 2010 model year Chevrolet Malibu and Pontiac G6 vehicles. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty Management system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Diagrams Seat Heater Switch: Diagrams Component Connector End Views Heated Seat Switch - Driver (KA1) Heated Seat Switch - Passenger (KA1) Page 9666 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 6389 Rear Compartment Lid Release Switch Rear Window Defogger Grid X1 Page 9693 within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 2416 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 7833 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 4250 4. Install the transmission mount to bracket upper nut. Hand tighten only. Caution: Refer to Fastener Caution 5. Tighten the transmission mount nut and bolts. * Tighten the transmission mount upper nuts to 50 Nm (37 lb ft). * Tighten the transmission mount lower bolts to 50 Nm (37 lb ft). 6. Install the left splash shield. 7. Install the left front tire and wheel. 8. Lower the vehicle. Transmission Rear Mount Replacement Transmission Rear Mount Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the left tire and wheel. 3. Using a suitable jack stand, support the rear of the powertrain. Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 5147 Page 4266 Transmission Mount Replacement - Left Side Transmission Mount Replacement - Left Side Page 9767 Pedal Positioning Sensor: Diagrams Component Connector End Views Brake Pedal Position (BPP) Sensor Page 7842 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Page 3218 Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 4. Remove the transaxle range switch lever nut and lever. 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. Service Precautions Power Steering Line/Hose: Service Precautions Power Steering Hose Disconnected Caution Caution: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system. Page 6394 Component Connector End Views Seat Adjuster Switch - Driver (LTZ) Seat Adjuster Switch - Driver (AG1) Page 4840 may cause damage to the brake hose and in turn may cause a brake fluid leak. 3. Remove the brake caliper (2) from the brake caliper bracket (3) and support the brake caliper (2) with heavy mechanic's wire (1), or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Rear Brake Caliper Replacement (See: Rear Brake Caliper Replacement). 4. Remove the brake pads (1) from the brake caliper bracket. 5. Remove the brake pad retainers (2) from the brake caliper bracket (3). 6. Remove the brake caliper bracket bolts (2). 7. Remove the rear brake caliper bracket. 8. Inspect the brake mounting and hardware. Refer to Rear Brake Caliper Hardware Replacement (See: Rear Brake Caliper Hardware Replacement ). 9. Inspect the brake caliper bracket. 10. Replace the brake caliper bracket if cracked or damaged. Installation Procedure Page 9503 Page 1105 Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Service and Repair Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement Removal Procedure 1. Remove the fuel pump module assembly. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor electrical connector (1). 3. Disengage the locking tab (2) on the fuel level sensor by pushing inward. 4. Remove the fuel level sensor (1) from the alignment feature (2). Installation Procedure Page 7854 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 2022 Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust (LAT) Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust (LE5 or LE9) Page 2943 ‹› If the MIL is illuminated, test the MIL control circuit terminal listed below for a short to ground. If the circuit tests normal, replace the IPC. * ECM terminal X1-27 for RPO LE5 * ECM terminal X1-12 for RPO LAT 3. Ignition ON, connect a 3A fused jumper wire between the MIL control circuit terminal listed below and ground. The MIL should illuminate. * ECM terminal X1-27 for RPO LE5 * ECM terminal X1-12 for RPO LAT ‹› If the MIL does not illuminate, test the MIL control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the IPC/bulb. 4. If all circuits/connections test normal, replace the ECM. Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Instrument Cluster Replacement (See: Instrument Panel, Gauges and Warning Indicators/Compass/Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement. setup, and programming Page 893 Throttle Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 2212 12. Remove the lower right and left HO2S (1, 2) using the J 39194-B. 13. Remove the left (front) catalytic converter to right (rear) catalytic converter nuts (3). 14. Remove the right (rear) catalytic converter bolt (5) and nuts (1) at the exhaust manifold. 15. Remove and discard the gasket (6). 16. Remove the right (rear) catalytic converter (2). 17. Remove the left (front) catalytic converter (4). 18. Remove and discard the left (front) catalytic converter to manifold gasket. 19. Inspect the catalytic converter-to-exhaust manifold flange. * Service Limit: 0.7 mm (0.028 in) max. * Standard: 0.7 mm (0.028 in) max. Installation Procedure Page 1095 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Page 2440 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LAT or LE5 or LE9) Crankshaft Position (CKP) Sensor (LY7) Page 2458 Page 1868 1. Install the lower tensioner bolt (2) into the tensioner (1). 2. Position the tensioner assembly in place. Warning To avoid personal injury, only remove the tensioner shipping clip when the tensioner is properly mounted to the engine and the accessory drive belt is in place and properly routed. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install but do not tighten the drive belt tensioner bolts (2). Note: In order to properly torque the lower bolt it will be necessary raise the front of engine and use a 15mm crows foot in order to gain access to the lower bolt and achieve proper torque. 4. Tighten the bolts (2) in sequence. 1. Tighten the top bolt to 22 Nm (16 lb ft). 2. Tighten the lower bolt to 50 Nm (37 lb ft) +90 degrees. 5. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair). 6. If tensioner assembly is new, use a 6 point socket on the drive belt tensioner hex boss (1) and rotate hex boss clockwise to release the tension and remove the shipping retainer by hand. Discard the shipping retainer. 7. Install the right side engine mount. Refer to Engine Mount Replacement (See: Engine Mount/Service and Repair/Engine Mount Replacement). Locations Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views Wheel Components 1 - Wheel Speed Sensor (WSS) - Right Front 2 - Wheel Speed Sensor (WSS) - Right Rear 3 Wheel Speed Sensor (WSS) - Left Rear 4 - Wheel Speed Sensor (WSS) - Left Front Page 4943 9. Disconnect the LF brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 10. Deplete the vacuum reserve from the vacuum brake booster by removing the vacuum check valve (1) from the vacuum brake booster grommet. Page 6080 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the MYLAR tape. If the MYLAR tape is damaged, use 3M product AL-36FR to replace the damaged MYLAR tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Page 628 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor (1) from the thermostat housing. Installation Procedure Page 1421 Fuse Block - Rear X3 Description and Operation Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Camshaft Position (CMP) Actuator System The camshaft position (CMP) actuator system is an electro-hydraulic operated device used for a variety of engine performance and operational enhancements. These enhancements include lower emission output through exhaust gas dilution of the intake charge in the combustion chamber, a broader engine torque range, and improved fuel economy. The CMP actuator system accomplishes this by changing the angle or timing of the camshaft relative to the crankshaft position. The CMP actuator simply allows earlier or later intake and exhaust valve opening during the four stroke engine cycle. The CMP actuator cannot vary the duration of valve opening, or the valve lift. During engine OFF, engine idling conditions, and engine shutdown, the camshaft actuator is held in the Park position. Internal to the CMP actuator assembly is a return spring and a locking pin. During non-phasing modes of the camshaft, the return spring rotates the camshaft back to the Park position, and the locking pin retains the CMP actuator sprocket to the camshaft. CMP Actuator System Operation The camshaft position (CMP) actuator system is controlled by the engine control module (ECM). The ECM sends a signal to a CMP actuator solenoid in order to control the amount of engine oil flow to a Cam Actuator passage. The pressurized engine oil is sent to unseat the locking pin, and to the vane and rotor assembly of the CMP actuator. There are 2 different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The Cam Actuator is attached to a camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position (CKP). Engine oil pressure (EOP), viscosity, temperature and engine oil level can have an adverse affect on Cam Actuator performance. Page 3061 Engine Control Module (ECM) X2 (LAT) Page 5149 Page 2301 Page 9918 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Page 1948 Intake Manifold: Service and Repair Intake Manifold Cover Replacement Intake Manifold Cover Replacement Removal Procedure 1. Remove the engine oil fill cap and tube. 2. If equipped with electric power steering, grasp the cover by the sides and pull up, disengaging the cover from grommets from the ball studs. 3. If equipped with hydraulic power steering, grasp the cover by the sides and pull up, disengaging the cover from grommets from the ball studs. Installation Procedure Page 4383 15. Crimp the seal retaining clamp (1) using J 35910 to 174 Nm (130 lb ft). 16. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Dimension a= 1.9 mm (5/64 in). Page 2260 1. Remove the bank 2 sensor 1 heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (). 2. Remove the exhaust manifold heat shield bolts. 3. Remove the exhaust manifold heat shield. Installation Procedure 1. Install the exhaust manifold heat shield. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust manifold heat shield bolts and tighten to 10 Nm (89 lb in). 3. Install the bank 2 sensor 1 HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (). Exhaust Heat Shield Replacement Exhaust Heat Shield Replacement Page 1657 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 2672 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor - Bank 1 Exhaust (LY7) Camshaft Position (CMP) Sensor - Bank 1 Intake (LY7) Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 10075 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 3696 2. Install the TFP switch assembly onto the control valve body assembly and install the bolts. Tighten the control valve body bolts to 12 Nm (9 lb ft). 3. Install the transaxle case side cover. 4. Start the engine, warm up the transaxle, and check for leaks. 5. Inspect for proper fluid level. Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 6. Reset the TAP values. Refer to Transmission Adaptive Functions See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Description and Operation. Page 286 Page 2779 1. Install the fuel level sensor (1) to the alignment feature (2). 2. Allow the locking tab (2) to lock into place. 3. Connect the fuel level sensor electrical connector (1). 4. Install the fuel pump module assembly. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Page 5890 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 7209 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Page 2171 Locations Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Locations Transmission Temperature Sensor/Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 553 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Page 6577 Electrical - Various Electrical Systems Malfunctions Body Control Module: Customer Interest Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Page 795 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor (1) from the thermostat housing. Installation Procedure Page 5944 3. Disconnect the seat to body harness connector (1). Disconnect the seat airbag connector (2). Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing into the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Slide the conduit away on the seat airbag harness and remove just enough tape on the body harness to access the wires to install the terminals and seals. Note Use caution when stripping insulation. Take care not to cut through the wire strands. 5. Slide the wire seals onto all four leads back enough to enable removal of the insulation. Install the blue seals (1) on the body harness and the white seals (2) on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Page 5978 Page 7256 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Page 9090 Page 4780 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Body/Paint - 2010 Exterior Paint Codes Paint: All Technical Service Bulletins Body/Paint - 2010 Exterior Paint Codes INFORMATION Bulletin No.: 10-08-51-001 Date: January 05, 2010 Subject: Exterior Paint Codes Models: 2010 Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Page 1519 Customer TPMS Information Page 8938 Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Page 7007 3. Lubricate and install the steering gear cylinder pipe seals (2) onto the steering gear cylinder pipes (1). Note: You must install the shorter steering gear cylinder pipe first. 4. Place the steering gear cylinder pipe (2) into the steering gear at the valve end of the steering gear (3). 5. Start the steering gear cylinder pipe fitting (1) in the steering gear (4) but do not torque it. 6. Place the longer steering gear cylinder pipe (2) into the steering gear at the valve end of the steering gear (3). 7. Start the steering gear cylinder pipe fitting (1) in the steering gear (4) but do not torque it. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the steering gear cylinder pipe retaining plate (2) and bolt (1) and tighten to 12 Nm (106 lb in). 9. Tighten the steering gear cylinder pipe fittings (3) to 19 Nm (14 lb ft). 10. Clean any excess power steering fluid from the vehicle and remove the drain pans. 11. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering/Power Steering Bleeding/Service and Repair). Page 1856 Page 6323 Heated Seat Control Module - Driver X1 (KA1) Page 9568 crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. Page 668 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 9880 Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 2. Remove the engine cover, if required. 3. Remove the fuel rail service port cap. 4. Wrap a shop towel around the fuel rail service port and using a small flat bladed tool, depress (open) the fuel rail test port valve. 5. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 6. Install the fuel rail service port cap. 7. Install the engine cover, if required. 8. Tighten the fuel fill cap. Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 2. Remove the engine cover, if required. 3. Remove the fuel rail service port cap. 4. Wrap a shop towel around the fuel rail service port and using a small flat bladed tool, depress (open) the fuel rail test port valve. 5. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 6. Install the fuel rail service port cap. 7. Install the engine cover, if required. 8. Tighten the fuel fill cap. Page 4112 Input Speed Sensor Seal Replacement Page 7922 Your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle not only meets, but exceeds government standards for side impact protection. GM recently introduced into production, changes that add to that protection. At no charge, your dealer will make similar changes to your vehicle, which was built before the production change. What We Will Do: To enhance the side impact protection, your GM dealer will update the wiring harness for both front seat side impact airbags. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 10085 Page 7569 Page 9553 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Page 3429 7. Remove the fuel rail bolts. Note: Use care when removing the fuel rail assembly in order to prevent damage to the fuel injector spray tips. 8. Pull the fuel rail back and upward in order to release the fuel injectors from the cylinder head ports. 9. Remove the fuel rail. Note: The fuel injector tip insulators may be located on the injector or may still be located in the cylinder head. Either way, ensure that all 4 injector tip insulators are removed and discarded. 10. Remove and discard the fuel injector tip insulators. Page 7720 3. Install the refrigerant pressure sensor wire harness connector. 4. Leak test the fittings using the J 39400-A. Page 3627 1 - Control Solenoid Valve Assembly (with Transmission Control Module) Page 5269 Auxiliary Power Outlet: Service and Repair 120-Volt Accessory Power Receptacle Replacement 120-Volt Accessory Power Receptacle Replacement Page 2191 11. Remove the auxiliary heater water pump hose clip (1) from the heater outlet hose. 12. Reposition the auxiliary heater water pump hose clamp at the thermostat housing. 13. Remove the auxiliary heater water pump hose (2) from the thermostat housing. 14. Reposition the heater inlet hose clamp at the thermostat housing. 15. Remove the heater inlet hose (3) from the thermostat housing. 16. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 17. Remove the ECT sensor, if necessary. Diagrams Ignition Control Module: Diagrams Component Connector End Views Ignition Control Module (ICM) (LZ4 or LZE) Rear Side Door Window Switch Replacement Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement Rear Side Door Window Switch Replacement Page 6352 Inflatable Restraint I/P Module Inflatable Restraint I/P Module Indicator Page 129 Page 5703 X407 Inline Harness Connector End Views X407 Body Harness to Generator Battery Assembly Harness (HP7) X411 Inline Harness Connector End Views X411 Body Harness to the Left Roof Rail Jumper Harness Page 414 Page 6744 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 7306 Always use a 4-wheel rotation. After rotation, check the wheel nuts for specified torque. Then set the tire pressure. Page 6014 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Page 9177 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors Tyco/AMP Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 1629 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 4824 10. Remove the brake hose-to-caliper bolt (1) from the brake caliper. 11. Remove the brake hose (3) from the brake caliper. 12. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3). 13. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 14. Remove the brake caliper guide pin bolts (2). 15. Remove the brake caliper from the caliper bracket. 16. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: * Restricted caliper guide pin movement * Looseness in the brake caliper mounting bracket * Seized or binding caliper guide pins * Split or torn boots 17. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Page 10070 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Page 9365 7. Raise and install the headliner. Perform the headliner replacement install steps 5 thru 24. Refer to Headlining Trim Panel Replacement (See: Interior Moulding / Trim/Headliner/Service and Repair) Verify that the electrical connector is connected to the sunroof motor/actuator. 8. Install the sunroof window. Adjust as necessary. Refer to Sunroof Window Replacement (See: Sunroof / Moonroof Panel/Service and Repair) 9. Initialize the sunroof motor. Refer to Sunroof Motor/Actuator Initialization/Teach Process (See: Sunroof / Moonroof Motor/Testing and Inspection) 10. Install the sunroof finishing lace. Refer to Sunroof Opening Trim Finish Lace Replacement (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair) 11. Inspect the sunroof for proper operation. Page 2591 1. Install a NEW air filter assembly. 2. Close the air cleaner cover. 3. Engage the air cleaner cover latches (1). 4. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 5. Install the air cleaner outlet duct to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Tighten the air cleaner outlet duct clamp at the air cleaner assembly to 4 Nm (35 lb in). Page 2023 Camshaft Position (CMP) Actuator Solenoid Valve - Intake (LAT) Camshaft Position (CMP) Actuator Solenoid Valve - Intake (LE5 or LE9) Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 1094 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Page 10525 Hazard Warning Switch: Service and Repair Hazard Warning Switch Replacement Page 345 Engine Control Module (ECM) X3 (LY7) Page 7142 8. Install the three pieces of foam to the attaching bracket starting at the top center inside the bracket and proceed down across the fuel lines, then at the inside of the bracket at the left and right positions of the center piece of foam. Finally, install the last two pieces of foam to the inside bracket at the left and right extended sides behind the retaining holes as shown above. 9. Reposition the radiator surge tank back onto the bracket and seat the two retaining tabs on the tank. 10. Drive the vehicle to verify that the noise is no longer present. Parts Information Order Adhesive Back Shim Stock from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 3389 Fuel Injector 5 (LY7) Fuel Injector 6 (LY7) Heater Core Cover Replacement Heater Core: Service and Repair Heater Core Cover Replacement Heater Core Cover Replacement Removal Procedure 1. Remove the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair). 2. Remove the center floor air outlet duct screws. 3. Remove the center floor air outlet duct. 4. Drill out the heater core cover heat stakes. 5. Remove the heater core cover screws. 6. Remove the heater core cover. Page 4668 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement Removal Procedure Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 1. Turn the ignition switch to the OFF position. 2. Clean the electronic brake control module (EBCM) to brake pressure modulator valve (BPMV) area of any accumulated dirt and foreign material. 3. Disconnect the electrical connector from the EBCM. 4. Remove the 4 EBCM bolts (1). 5. Separate the EBCM (1) from the BPMV by carefully pulling the components apart. Page 9197 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 6618 Fuse Block - Rear X1 Service and Repair Tail Lamp Control Module: Service and Repair Tail Lamp Control Module with Bulb Replacement Page 5051 5. Disconnect the negative battery cable from the battery. Connect Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Clean any existing oxidation from the contact face of the battery terminal and battery cable using a wire brush before installing the battery cable to the battery terminal. 1. Connect the negative battery cable to the battery and tighten to 17 Nm (13 lb ft). 2. Install the battery cover. 1. Install the locking tab next to the strut tower first. 2. Install the locking tab next to the engine second. 3. Install the locking tab next to the powertrain control module (PCM) last. Page 6233 Center High Mounted Stop Lamp (CHMSL) Control Solenoid Valve Assembly (MH2) Page 3210 Throttle Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 9266 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Page 8534 Vehicle Communication Interface Module (VCIM) X3 (UE1) Page 2233 5. Install the exhaust manifold heat shield and bolts. Tighten the bolts to 10 Nm (89 lb in). Note: A special anti-seize compound is used on the HO2S threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 6. Coat the threads of the HO2S with anti-seize compound. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) 7. Install the HO2S using J 39194-B. Tighten the sensor to 42 Nm (31 lb ft). Page 6316 Component Connector End Views Hazard Warning Switch Headlamp - Left High Beam Page 7609 2. Install the evaporator. 3. Install new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 4. Install the thermal expansion valve. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the thermal expansion valve screws and tighten to 7 Nm (62 lb in). Page 7643 2. Install the heater core cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the heater core cover screws and tighten to 1.5 Nm (13 lb in). 4. Install the center floor air outlet duct. 5. Install the upper floor air outlet duct screws and tighten to to 1.5 Nm (13 lb in). 6. Install the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Housing Assembly HVAC/Service and Repair). Page 2344 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 9540 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 607 Traction Control Switch: Diagrams Component Connector End Views Traction Control Switch (TCS) Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Page 3130 1. Lubricate the CKP sensor O-ring seal with clean engine oil. 2. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CKP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 5. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 6. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Page 9233 Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch Page 4352 Figure 9 1. Once TIS2WEB is launched and you're at the main screen, select Snapshot, indicated with a arrow in Figure 8. 2. Select the Upload from Handheld button to launch the device selection screen just like the TIS 2000 procedure described above. Figure 10 3. Select the top button, "Upload from Handheld" which will launch the screen displayed in Figure 10. Make sure the Tech 2(R) is connected to the computer and plugged in. Select Tech 2(R) under Device and select OK. The screen of your Tech 2(R) should start blinking and a line will start scrolling across the screen indicating it is communicating with your computer. Figure 11 Page 4596 8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95. 10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body and transmission control module (TCM) assembly (5). Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 12. Remove the control solenoid valve assembly filter plate (6). * Discard the filler plate. It is not reusable. * Inspect the pressure switch manifold seals for damage or contamination. Replace the control solenoid valve assembly as necessary. * Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage around the PCS seals. Replace the upper channel plate as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (1). Page 5604 Throttle Body Campaign - Airbag Readiness Light/Service Airbag Message Technical Service Bulletin # 10085D Date: 110203 Campaign - Airbag Readiness Light/Service Airbag Message CUSTOMER SATISFACTION Bulletin No.: 10085D Date: February 03, 2011 Subject: 10085D - Airbag Readiness Light/Service Airbag Message - Replace Connectors Models: 2008 Buick Enclave 2010 Chevrolet Malibu 2008 GMC Acadia 2010 Pontiac G6 2008 Saturn OUTLOOK Supercede: The Service Procedure in this bulletin has been revised. All vehicles will not require the replacement of the front seat-mounted side impact airbag connectors.Please discard all copies of bulletin 10085C, issued November 2010. Condition Certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may experience wear which could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact air bag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG System warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG System DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Correction Dealers are to replace the front seat-mounted side impact airbag connectors. Vehicles Involved Involved are certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Part Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your Page 5162 Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Audio - Radio Does Not Mute Enough When Using OnStar(R) Navigation System: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 7039 7. Wipe off any excessive grease on the intermediate shaft to avoid damage from drips on the carpet. 8. Install the instrument panel insulator panel - left side. 9. Verify that the noise is no longer present. Condition 2 There may be interference between the clamp and the steering gear input shaft. The clamp is beveled and if forced down on the input shaft too hard, it may cause a loose fit with the intermediate shaft to input shaft joint. Correction 2 To correct this condition, perform the following steps: 1. Remove the intermediate shaft pinch bolt at the steering gear end. 2. Install a new bolt, GM P/N 07845238, but do not tighten the bolt at this time. 3. Pry the clamp up using a pry bar to position the bolt into the upper part of the groove as shown above. This will position the clamp off the bevel. 4. While keeping the clamp in the upper position, tighten the bolt. Tighten Tighten the bolt to 49 Nm (36 lb ft). 5. Verify that the clunk noise is no longer present. Condition 3 Important This condition ONLY applies to 2004-2007 Chevrolet Malibu/Maxx and 2005-2007 Pontiac G6. Some customers may comment on a knocking or rattling type noise from the front of the vehicle when driven at low speeds and over bumps. The noise only occurs when the steering wheel is in the straight ahead position and sounds like the noise is in the left suspension of the vehicle or directly in front of the driver. Correction 3 1. Ensure the noise is not caused by Condition # 1. 2. Determine the source of the noise. Install the chassis ears at the following locations: - sway bar link - one side at a time - upper strut mount - one side at a time - steering gear near the pinion area - base of the steering column housing - radiator surge tank 3. If the noise is coming from the upper strut mount or sway bar link, replace as necessary and retest. 4. For 2004-2006 Chevrolet and Pontiac model year vehicles, the noise may be coming from the radiator surge tank area. (The 2007 model year vehicles use a different style radiator surge tank - refer to Step 9.) 5. If the noise is coming from the radiator surge tank, release the two retaining tabs holding the radiator surge tank and reposition the tank away from the attaching bracket and isolate with closed cell foam. 6. Cut three pieces of closed cell foam, P/N P46515 (or equivalent), into 25 mm (1 in) by 102 mm (4 in) pieces. 7. Cut two pieces of closed cell foam into 25 mm (1 in) by 6 mm (1/4 in) pieces. Page 374 Page 7783 Repairs and Inspections Required After a Collision: Service and Repair Supplemental Inflatable Restraints Repairs and Inspections Required After a Collision Accident With or Without Air Bag Deployment - Component Inspections Warning Proper operation of the SIR sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment in a collision or deployment for conditions less severe than intended. After a collision, inspect the following components as indicated. If any damage is detected, replace the component. If damage to the mounting points or mounting hardware is detected, repair the component or replace the hardware as needed. * Steering column-Perform the steering column accident damage checking procedures. Refer to Steering Column Accident Damage Inspection ( See: Steering and Suspension/Steering/Steering Column/Testing and Inspection/Initial Inspection and Diagnostic Overview). * Instrument panel (I/P) knee bolsters and mounting points-Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. * I/P brackets, braces, etc.-Inspect for bending, twisting, buckling, or any other type of damage. * Seat belts-Perform the seat belt operational and functional checks. Refer to Seat Belt System Operational and Functional Checks (See: Seat Belt Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview). * Seats and seat mounting points-Inspect for bending, twisting, buckling, or any other type of damage. * Passenger seat bottom with passenger presence system (PPS)-Check for any DTCs or problems that may cause the PPS not to function properly. * The roof and headliner mounting points Frontal Inflator Module Deployment After a collision involving air bag deployment, replace the following components. Note: The front passenger seat is equipped with a PPS, which detects an occupant. If the requirements for disabling the I/P air bag are met then the PPS will communicate with the sensing and diagnostic module (SDM) to disable/turn OFF the I/P air bag, even in a accident. For more information on the PPS refer to SIR System Description and Operation (See: Air Bag Systems/Description and Operation/SIR System). * Inflatable restraint I/P module, if deployed and after performing the necessary inspections listed above * Inflatable restraint steering wheel module * Inflatable restraint SDM * Inflatable restraint front end sensor, left/right * Inflatable restraint seat belt pretensioners Perform additional inspections on the following components. * Steering wheel module coil and the coil wiring pigtail-Inspect for melting, scorching, or other damage due to excessive heat. * Mounting points or mounting hardware for the I/P, steering wheel module, SDM, and pretensioners-Inspect for any damage and repair or replace each component as needed. Accident With Side Air Bag Deployment - Component Replacement and Inspections After a collision involving side air bag deployment, replace the following components. * Inflatable restraint side impact sensors (SIS), left/right, on the side of the impact * Inflatable restraint roof rail module, left/right, on the side of the impact * Inflatable restraint SDM * Inflatable restraint seat belt pretensioner Perform additional inspections on the following components. * Mounting points or mounting hardware for the SIS-Inspect for any damage and repair or replace each component as needed. * Mounting points or mounting hardware for the roof rail module (left/right) on the side of impact-Inspect for any damage and repair or replace each component as needed. * Mounting points or mounting hardware for the SDM and seat belt pretensioners-Inspect for any damage and repair or replace each component as needed. Page 2106 Coolant Reservoir: Service and Repair Radiator Surge Tank Outlet Hose/Pipe Replacement Radiator Surge Tank Outlet Hose/Pipe Replacement Page 4273 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH8) Page 10299 Dimmer Switch: Service and Repair Instrument Panel Lamp Dimmer Switch Replacement Page 2793 Page 4177 7. Remove the transmission shift control nuts (1). 8. Remove the transmission shift control (2). Installation Procedure 1. Install the transmission shift control (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission shift control nuts (1) and tighten to 25 Nm (18 lb ft). Wheel Drive Shaft Outer Joint Inspection Constant Velocity Joint: Testing and Inspection Wheel Drive Shaft Outer Joint Inspection Wheel Drive Shaft Outer Joint Inspection Special Tools J 8059 Snap Ring Pliers Disassembly Procedure 1. Remove the outer constant velocity (CV) joint and boot from the wheel drive shaft. Refer to Wheel Drive Shaft Replacement (See: Service and Repair/Wheel Drive Shaft Replacement). 2. Remove any grease from the CV joint. 3. Using the J 8059, remove the retaining ring (3) from the wheel drive shaft (4). Page 7772 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the service port valve core using J 46246 or equivalent. Tighten the service port valve core to 2.5 Nm (22 lb in). 2. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 3. Leak test the fittings using the J 39400-A. Page 6866 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Page 6580 Fuse Block - Underhood X4 Page 5371 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 3734 Transmission Speed Sensor: Service and Repair 6T70/6T75 - Automatic Transmission Output Speed Sensor Replacement Output Speed Sensor Replacement Input Speed Sensor Replacement Input Speed Sensor Replacement Page 4146 movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions See: Description and Operation. Page 3117 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 9127 Page 3946 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: The correct thread engagement is critical. Cross-threaded fittings can achieve proper tightness and still leak. 2. Install the oil cooler fitting to the radiator and tighten to 38 Nm (28 lb ft). 3. Install the transaxle oil cooler hoses to the oil cooler fittings on the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: 6T30/6T40/6T45 - Automatic Transmission/Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 5. Adjust the transmission fluid level. 6. Inspect for fluid leaks. Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Removal Procedure Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. Page 5616 Wheel Speed Sensor (WSS) - Left Front Electrical - Various Electrical Concerns/False Messages Door Switch: All Technical Service Bulletins Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Page 5237 within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) Page 7447 3. Remove the right hand side window defogger duct. 4. Disconnect the wire harness clip at the right air outlet duct. 5. Remove the right air outlet duct screws. 6. Remove the right air outlet duct. Installation Procedure Page 7450 3. Remove the windshield defroster duct. Installation Procedure 1. Install the windshield defroster duct. 2. Install the I/P pad. Refer to Instrument Panel Upper Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Upper Trim Panel Replacement). Side Window Defogger Outlet Duct Replacement - Left Side Side Window Defogger Outlet Duct Replacement - Left Side Removal Procedure 1. Remove the instrument panel (I/P) assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Page 3393 * Injector Ckt Short Volts Test Status ‹› Each parameter should toggle between OK and Not Run or Not Run and OK. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at a fuel injector. 2. Ignition ON, verify that a test lamp illuminates between the ignition circuit terminal A and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, test or replace the fuel injector. 3. Ignition OFF, connect a J 44603 - Injector Test Lamp between the control circuit terminal B and the ignition circuit terminal A of each fuel injector one at a time. 4. Engine cranking, the test lamp should flash for each injector. ‹› If the test lamp is always ON, test the appropriate control circuit for a short to ground. If the circuit tests normal, replace the engine control module (ECM). ‹› If the test lamp is always OFF, test the appropriate control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM. 5. If all circuits test normal, test or replace the fuel injector. Refer to Fuel Injector Solenoid Coil Test (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Injector Solenoid Coil Test). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Injector Replacement (See: Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming Page 2886 Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 8293 * J-38125-8 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Page 100 Warranty Information (Saab U.S. Models) Disclaimer Page 2686 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 5307 Fuse: Locations Instrument Panel Fuse Block - Owners Manual INSTRUMENT PANEL FUSE BLOCK The instrument panel fuse block is located on the instrument panel near the floor on the passenger side of the vehicle. Remove the panel cover to access the fuse block, then remove the fuse block cover to access the fuses. The vehicle might not have all the fuses and features listed. Page 4831 10. Remove the brake pad retainers (2) from the disc brake caliper bracket. 11. Remove the brake caliper guide pins (2) from the brake caliper mounting bracket (4). 12. Remove the brake caliper pin boots (3) from the brake caliper mounting bracket (4). Installation Procedure 1. Apply a thin coat of high temperature silicone lube to the brake caliper guide pin boots. 2. Install the brake caliper pin boots (3) into the brake caliper mounting bracket (4). Do not hammer the caliper pin boots into the bracket. Ensure that the caliper pin boots are fully seated in the bracket. 3. Install the brake caliper guide pins (2) to the brake caliper mounting bracket (4). Page 8513 Speaker - Right Front (UW5) Speaker - Right Front Tweeter Page 5649 Automatic Transmission Manual Shift Switch - Left (KB7) Page 5669 Brake Pedal Position (BPP) Sensor Page 6849 1. Slide the steering wheel position sensor into place and remove the locating pin. 2. Connect any electrical connectors as needed. 3. Connect the intermediate steering shaft to the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering/Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 4. Remove anti-rotation pin J 42640. Diagrams Seat Heater Switch: Diagrams Component Connector End Views Heated Seat Switch - Driver (KA1) Heated Seat Switch - Passenger (KA1) Page 6685 Ensure that the appropriate wire colors match up (as noted in Step 4) when the connection is made between the seat airbag harness and body harness. 10. Slide all four terminals (2) into the appropriate connector body as shown above. Install the blue terminal position assurance (TPA) devices onto the connector ends. 11. Add NyoGel 760 Lubricant (dielectric lubricant), P/N 12377900 (in Canada, use P/N 10953529) (Saturn retailers, use P/N 12345579) to the terminals on both sides of the connections. 12. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the body harness up to the back of the connector. 13. Reinstall the conduit on the seat airbag harness. 14. Repeat the above procedure on the passenger seat. Reinstall Seats 1. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 2. Reconnect the seat to body harness connector and the seat airbag connector. Reroute Harness and Secure Connector Follow the procedure below to re-route and attach the harness connector to the body harness bundle: 1. The original seat airbag connector was attached with a clip to the bottom of the seat (2) as shown above. 2. Using two wire ties, secure the seat airbag connector to the seat wire bundle as shown. Ensure that there is enough slack for full range of motion of the seat. 3. Inspect the wires through the full range of motion of the seat again as in Step 2. Ensure that the wires have been secured in an orientation that allows full seat motion with adequate clearance to the connectors and sufficient slack in the wires. 4. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 5. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Page 6876 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Power Steering Fluid Reservoir Replacement - Off Vehicle Power Steering Fluid Reservoir: Service and Repair Power Steering Fluid Reservoir Replacement Off Vehicle Power Steering Fluid Reservoir Replacement - Off Vehicle Disassembly Procedure 1. Remove the power steering pump. Refer to Power Steering Pump Replacement (See: Power Steering Pump/Service and Repair/Power Steering Pump Replacement). 2. Place the power steering pump on a fixed, flat surface, with the power steering pump shaft facing upward. 3. Using a screwdriver, position the power steering fluid reservoir retaining clip tabs outward, and slide them way from the power steering pump. 4. Remove the power steering fluid reservoir from the power steering pump. 5. Remove and discard the power steering fluid reservoir O-ring seal. Page 6222 Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake (LY7) Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust (LY7) Page 7732 Page 1028 4. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 5. Install the shift control cable to transaxle range switch lever and verify proper operation. Page 3200 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). 6. Remove the alignment tool. Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 7. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Page 3031 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 8202 Page 2933 Note: Rotate the pigtail 90 degrees from vertical before securing the fastener. 1. Install the knock sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the knock sensor bolt and tighten to 25 Nm (18 lb ft). 3. Install the knock sensor electrical connector pigtail (6) clip to the oil level indicator tube bracket. 4. Connect the engine wiring harness electrical connector (1) to the knock sensor pigtail electrical connector (6). 5. Lower the vehicle. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Page 4734 10. Remove the brake pad retainers (2) from the disc brake caliper bracket. 11. Remove the brake caliper guide pins (2) from the brake caliper mounting bracket (4). 12. Remove the brake caliper pin boots (3) from the brake caliper mounting bracket (4). Installation Procedure 1. Apply a thin coat of high temperature silicone lube to the brake caliper guide pin boots. 2. Install the brake caliper pin boots (3) into the brake caliper mounting bracket (4). Do not hammer the caliper pin boots into the bracket. Ensure that the caliper pin boots are fully seated in the bracket. 3. Install the brake caliper guide pins (2) to the brake caliper mounting bracket (4). Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 1594 Tires: Description and Operation All Seasons Tires Description All Seasons Tires Description This vehicle is equipped with steel belted all-season radial tires as standard equipment. These tires qualify as snow tires, with a higher than average rating for snow traction than the non-all season radial tires previously used. Other performance areas, such as wet traction, rolling resistance, tread life, and air retention, are also improved. This is done by improvements in both tread design and tread compounds. These tires are identified by an M + S molded in the tire side wall after the tire size. The suffix MS is also molded in the tire side wall after the TPC specification number. Page 6399 Seat Belt Switch - Driver Seat Belt Switch - Passenger Page 6015 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Page 5613 Vehicle Communication Interface Module (VCIM) X1 (UE1) Page 335 Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Page 3284 Canister Purge Solenoid: Diagrams Component Connector End Views Evaporative Emission (EVAP) Canister Purge Solenoid Valve (LAT or LE5 or LE9) Evaporative Emission (EVAP) Canister Purge Solenoid Valve (LY7) Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ........................................ 345-414 kPa (50-60 psi). Verify the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute Page 7271 Customer TPMS Information Page 1415 Fuse Block - Rear Top View Page 3998 Important: Ensure that the ignition key is in the RUN position. Do not attempt to insert the park lock cable with the key in any other position. 6. Install the cable (1) into the inhibitor housing. 7. Turn key to LOCK position. 8. Attach the park lock cable to the shift control base. Ensure the park lock cable retainer (2) is fully secured to the shift control base. 9. Install the park lock cable on the park lock lever by sliding the cable end (1) over the park lock lever pin. 10. Inspect the functional operation of the park/lock cable. Refer to Park Lock Cable Adjustment (See: Adjustments/4T45-E - Automatic Transmission). 11. Install the knee bolster. Refer to Driver Knee Bolster Panel Replacement (See: Restraint Systems/Knee Diverter/Service and Repair). 12. Install the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 13. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Page 9529 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 5692 X310 Inline Harness Connector End Views X310 Body Harness to Passenger Seat Harness Page 1124 2. File the lower hole until the outer flange slot matches the inner flange slot. 3. Connect the strut to the knuckle. Refer to Strut Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Strut/Strut Assembly Replacement). 4. Adjust the camber to specification by moving the top of the wheel in or out. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the strut to knuckle nuts. Tighten the nuts to 120 Nm (89 lb ft). Front Caster Adjustment Front Caster Adjustment The front caster is not adjustable. If the front caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Replace any damaged suspension components as necessary. Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Page 3510 Camshaft Position (CMP) Sensor - Bank 2 Exhaust (LY7) Page 4592 Transmission Control Module (TCM) (MN5 with LZ4 or LZE) Page 3581 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor. Installation Procedure Page 524 1 - Brake Pedal Position (BPP) Sensor 2 - Accelerator Pedal Position (APP) Sensor 3 - Accelerator Pedal 4 - Brake Pedal Description and Operation Electronic Throttle Actuator: Description and Operation Throttle Actuator Control (TAC) System Description The engine control module (ECM) is the control center for the throttle actuator control (TAC) system. The ECM determines the driver's intent based on input from the accelerator pedal position sensors, then calculates the appropriate throttle response based on the throttle position sensors. The ECM achieves throttle positioning by providing a pulse width modulated voltage to the throttle actuator motor. The throttle blade is spring loaded in both directions, and the default position is slightly open. Modes Of Operation Normal Mode During the operation of the TAC system, several modes, or functions, are considered normal. The following modes may be entered during normal operations: * Minimum pedal value-At key-up, the ECM updates the learned minimum pedal value. * Minimum throttle position values-At key-up, the ECM updates the learned minimum throttle position value. In order to learn the minimum throttle position value, the throttle blade is moved to the Closed position. * Ice break mode-If the throttle blade is not able to reach a predetermined minimum throttle position, the ice break mode is entered. During the ice break mode, the ECM commands the maximum pulse width several times to the throttle actuator motor in the closing direction. * Minimum pedal value-At key-up, the ECM updates the learned minimum pedal value. * Battery saver mode-After a predetermined time without engine RPM, the ECM commands the Battery Saver mode. During the Battery Saver mode, the TAC module removes the voltage from the motor control circuits, which removes the current draw used to maintain the idle position and allows the throttle to return to the spring loaded default position. Reduced Engine Power Mode When the ECM detects a condition with the TAC system, the ECM may enter a reduced engine power mode. Reduced engine power may cause one or more of the following conditions: * Acceleration limiting-The ECM will continue to use the accelerator pedal for throttle control, however, the vehicle acceleration is limited. * Limited throttle mode-The ECM will continue to use the accelerator pedal for throttle control, however, the maximum throttle opening is limited. Service and Repair Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Special Tools * EN-36017 - Valve Guide Seal Remover * EN-43649 - Valve Spring Compressor * EN-43649-10 - Valve Spring Compressor Adaptor Set * EN-43653 - Flywheel Holding Tool For equivalent regional tools refer to Special Tools (See: Tools and Equipment). Removal Procedure Note: Prevent the crankshaft from rotating clockwise or counterclockwise before using compressed air in the cylinder. Rotation of the crankshaft may cause damage to EN-43653 - holding tool. 1. If equipped, with a manual transmission leave the transmission in first gear with the vehicle on the ground and the parking brake set. 2. If equipped, with an automatic transmission, remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 3. Install EN-43653 - holding tool. 4. Remove the camshaft. Refer to Intake Camshaft and Valve Lifter Replacement (See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Intake Camshaft and Valve Lifter Replacement) or Exhaust Camshaft and Valve Lifter Replacement (See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Exhaust Camshaft and Valve Lifter Replacement). 5. Remove the camshaft roller followers (1). Page 3089 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 10262 Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Service and Repair Front Door Hinge: Service and Repair Front Side Door Upper Hinge and Lower Hinge Replacement Page 7301 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. For combination repair/plug units skip this step. Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Page 9104 Page 9333 Installation Procedure 1. Position the sunroof motor to the sunroof module. 2. Push the sunroof motor straight upward to engage the drive gear between the cables housed within the sunroof cable drive tubes. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sunroof actuator screws to the sunroof actuator and tighten the screws to 4 Nm (35 lb in). 4. Connect the electrical connector to the sunroof motor. 5. Install the headliner. Refer to Headlining Trim Panel Replacement (See: Interior Moulding / Trim/Headliner/Service and Repair). 6. Initialize/teach the sunroof motor. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for programming and setup information. 7. Inspect the sunroof for proper operation. Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools * J 8059 Snap Ring Pliers (Parallel Jaw) * J 35910 Drive Axle Seal Clamp Pliers Removal Procedure Caution: Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. 1. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining clamp with a side cutter. Discard the retaining clamp. 2. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal retaining clamp. 3. Separate the inboard seal from the trilobal tripot bushing (3) at the large diameter. 4. Slide the seal away from the joint along the halfshaft bar. Page 7232 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Page 5967 Page 9112 Locations Daytime Running Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 4775 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Page 7405 Wheel Bearing: Service and Repair Rear Suspension Rear Wheel Bearing and Hub Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 4. Disconnect the electrical connector from the wheel speed sensor. 5. Remove the 4 wheel bearing/hub assembly nuts. 6. Remove the wheel bearing/hub assembly from the knuckle. Installation Procedure Page 4203 3. Attach the transmission range selector lever cable retainer (1). 4. Install the transmission range selector lever cable to the transmission control lever base. Insure the cable retainer (1) is fully secured to the transmission control lever base. 5. Connect the transmission range selector lever cable terminal (2) to the shift lever pin. 6. Install the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). Page 6655 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 8242 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Bosch Connectors Bosch Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 5953 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 8243 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Page 6957 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Page 5806 "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN(s) 19118426 and 20968489 will not be eligible for RIM management. * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Service Procedure Replace Wire Harness Connector 2010 Chevrolet Malibu and 2010 Pontiac G6 Tools Required - J 38125-7 Crimp Tool - J 38125-6 Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Seat shown out-of-vehicle for illustration purposed Diagrams Auxiliary Water Pump: Diagrams Component Connector End Views Heater Coolant Pump (HP7) Page 6950 Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor (NVH) Page 5229 Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Page 7141 7. Wipe off any excessive grease on the intermediate shaft to avoid damage from drips on the carpet. 8. Install the instrument panel insulator panel - left side. 9. Verify that the noise is no longer present. Condition 2 There may be interference between the clamp and the steering gear input shaft. The clamp is beveled and if forced down on the input shaft too hard, it may cause a loose fit with the intermediate shaft to input shaft joint. Correction 2 To correct this condition, perform the following steps: 1. Remove the intermediate shaft pinch bolt at the steering gear end. 2. Install a new bolt, GM P/N 07845238, but do not tighten the bolt at this time. 3. Pry the clamp up using a pry bar to position the bolt into the upper part of the groove as shown above. This will position the clamp off the bevel. 4. While keeping the clamp in the upper position, tighten the bolt. Tighten Tighten the bolt to 49 Nm (36 lb ft). 5. Verify that the clunk noise is no longer present. Condition 3 Important This condition ONLY applies to 2004-2007 Chevrolet Malibu/Maxx and 2005-2007 Pontiac G6. Some customers may comment on a knocking or rattling type noise from the front of the vehicle when driven at low speeds and over bumps. The noise only occurs when the steering wheel is in the straight ahead position and sounds like the noise is in the left suspension of the vehicle or directly in front of the driver. Correction 3 1. Ensure the noise is not caused by Condition # 1. 2. Determine the source of the noise. Install the chassis ears at the following locations: - sway bar link - one side at a time - upper strut mount - one side at a time - steering gear near the pinion area - base of the steering column housing - radiator surge tank 3. If the noise is coming from the upper strut mount or sway bar link, replace as necessary and retest. 4. For 2004-2006 Chevrolet and Pontiac model year vehicles, the noise may be coming from the radiator surge tank area. (The 2007 model year vehicles use a different style radiator surge tank - refer to Step 9.) 5. If the noise is coming from the radiator surge tank, release the two retaining tabs holding the radiator surge tank and reposition the tank away from the attaching bracket and isolate with closed cell foam. 6. Cut three pieces of closed cell foam, P/N P46515 (or equivalent), into 25 mm (1 in) by 102 mm (4 in) pieces. 7. Cut two pieces of closed cell foam into 25 mm (1 in) by 6 mm (1/4 in) pieces. Page 3197 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (ME7 or MN5) Duct Air Temperature Sensor Replacement - Upper Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Duct Air Temperature Sensor Replacement - Upper Page 9094 OnStar(R) - Availability for Hearing Impaired Navigation System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 549 Seat Adjuster Switch - Passenger (LTZ) Page 7032 8. Install the three pieces of foam to the attaching bracket starting at the top center inside the bracket and proceed down across the fuel lines, then at the inside of the bracket at the left and right positions of the center piece of foam. Finally, install the last two pieces of foam to the inside bracket at the left and right extended sides behind the retaining holes as shown above. 9. Reposition the radiator surge tank back onto the bracket and seat the two retaining tabs on the tank. 10. Drive the vehicle to verify that the noise is no longer present. Parts Information Order Adhesive Back Shim Stock from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5226 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors Tyco/AMP Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 6175 Fuse Block - Rear X1 Page 1400 Fuse Block - Underhood Top View (LAT) Page 5146 Page 8090 1. Turn OFF the ignition. 2. Remove the ignition key. 3. Put on safety glasses. 4. Remove the seat belt retractor pretensioner from the vehicle. Refer to Seat Belt Retractor Pretensioner Replacement - Front (See: Removal and Replacement). 5. When carrying a seat belt retractor pretensioner to the deployment area, keep fingers clear of the seat belt webbing. 6. Clear a space on the ground about 1.85 m (6 ft) in diameter (a) for deployment of the seat belt pretensioner. If possible, use a paved, outdoor location free of activity. Otherwise, use a space free of activity on the shop floor. Make sure you have sufficient ventilation. 7. Make sure no loose or flammable objects are in the area. 8. Place the J 39401-B in the center of the cleared area. 9. Fill the fixture plastic reservoir with water or sand. Page 3687 Page 6392 Repeater Lamp - Left Front Page 9560 Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 3969 Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement Special Tools * EN-36017 - Valve Guide Seal Remover * EN-43649 - Valve Spring Compressor * EN-43649-10 - Valve Spring Compressor Adaptor Set * EN-43653 - Flywheel Holding Tool For equivalent regional tools refer to Special Tools (See: Tools and Equipment). Removal Procedure Note: Prevent the crankshaft from rotating clockwise or counterclockwise before using compressed air in the cylinder. Rotation of the crankshaft may cause damage to EN-43653 - holding tool. 1. If equipped, with a manual transmission leave the transmission in first gear with the vehicle on the ground and the parking brake set. 2. If equipped, with an automatic transmission, remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 3. Install EN-43653 - holding tool. 4. Remove the camshaft. Refer to Intake Camshaft and Valve Lifter Replacement (See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Intake Camshaft and Valve Lifter Replacement) or Exhaust Camshaft and Valve Lifter Replacement (See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Exhaust Camshaft and Valve Lifter Replacement). 5. Remove the camshaft roller followers (1). Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) A/C - Poor Cooling Performance/Condenser Fan Fuse Blown Fuse: All Technical Service Bulletins A/C - Poor Cooling Performance/Condenser Fan Fuse Blown TECHNICAL Bulletin No.: 09-01-38-005 Date: October 09, 2009 Subject: Poor A/C Performance, Cooling Fan Fuse Blown (Install Revised Fuse And Wiring) Models: 2008-2010 Chevrolet Malibu 2006-2010 Pontiac G6 2007-2010 Saturn AURA All with RPO LY7, LZ4, LZ9 or LZE V6 Engine Condition Some customers may comment on poor A/C cooling performance. Technicians may find that the cooling fan fuse is blown. Cause High cooling fan start up loads may cause the 30-amp cooling fan fuse, located in the underhood fuse block, to blow. The lack of air flow through the A/C condenser, caused by the inoperative high-speed cooling fan, may affect the condenser's ability to dissipate heat. Correction Use the following procedure to install a heavier gauge power feed wire from the underhood fuse block to the cooling fan. After the wiring update is completed, replace the 30-amp cooling fan fuse in the underhood fuse block with a 40-amp fuse. 1. Disconnect and remove the battery. Refer to Battery Replacement in SI. 2. Remove the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 3. Disconnect the underhood fuse block from it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. It is only necessary to raise the fuse block enough to access the harness connectors. Do not remove the complete assembly from the vehicle. 4. Locate the engine wiring harness junction block assembly (X1) on the back (underside) of the underhood fuse block and disconnect it from the underhood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 5. Find pin A2, Circuit 532, cooling fan motor supply voltage. Refer to Electrical Center Identification Views, Fuse Block-Underhood X1 in SI. 6. Remove the harness back cover. Remove the TPA (terminal position assurance) clip and remove connector A2 from the junction block. Cut the terminal off and tape the wire end with electrical tape. 7. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 8. Locate the electrical connector to the right cooling fan and disconnect the wiring connector from the fan. 9. Disengage pin B, wire 3 GY, circuit 532, cooling fan motor supply voltage, from the connector housing (pull to seat terminal). Cut the terminal off of the wire and remove the wire from the connector housing. 10. Tape the end of the wire with electrical tape. 11. Prepare a 1.82 m (6 ft) section of automotive grade 5.0 mm (10 GA) wire and an equal length of 6 mm (1/4 in) flexible plastic conduit, GM P/N 12051375. 12. Run the new wire through the fan wire connector housing as shown. 13. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 14. Strip the wire insulation as required and install the terminal, GM P/N 12033997, on the wire. Secure the wire and terminal into the fan wire Page 10775 Windshield Washer Reservoir: Service and Repair Windshield Washer Solvent Container Replacement Windshield Washer Solvent Container Replacement Removal Procedure 1. Open the hood. 2. Remove the washer container filler tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement (See: Windshield Washer Solvent Container Filler Tube Replacement). 3. Remove the front wheelhouse panel splash shield. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 4. Disconnect the washer pump hose (1) from the windshield washer hose (2). 5. Disengage the hose from the washer container. 6. Drain the washer solvent in a suitable clean container. Page 9574 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 9668 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 1494 Disclaimer Page 4666 Page 5679 X130 Engine Harness to Fuel Injector Harness (LY7) Page 7072 15. Remove the wheel speed sensor wiring harness from the upper control arms and the support. 16. Remove the upper control arm nuts and bolts from the support. 17. Remove the upper control arms from the support. 18. Remove the stabilizer shaft from the support. Installation Procedure Note: When transferring any suspension components, refer to each suspension component replacement procedure for the proper torque specifications. 1. Install the rear stabilizer shaft assembly on the support. Refer to Stabilizer Shaft Replacement (See: Stabilizer Bar/Service and Repair/Rear Suspension). Page 1061 1 - Outside Rearview Mirror - Passenger 2 - Door Frame 3 - Door Latch - Passenger 4 - Inflatable Restraint Side Impact Sensor (SIS) - Right 5 - Window Switch - Passenger 6 - Speaker - Right Front 7 - Window Motor - Passenger 8 - Door Lock Switch - Passenger 9 - Courtesy Lamp - Right Front Door Rear Door Components Service and Repair Upper Side Moulding / Trim: Service and Repair Body Panel Paint Protector Replacement 1. The paint protective film and vehicle surface temperature should be 13-32°C (55-90°F) for best results. 2. Automatic car washes should be avoided for at least 24 hours after the paint protective film application. 3. Wipe the vehicle surface with isopropyl alcohol or flash naptha at the application area. 4. Dry the surface with a clean lint-free cloth. 5. Create a mixture of 25 percent isopropyl alcohol and 75 percent water and two drops of baby shampoo per 16 oz of fluid mixture. 6. Remove the backing liner from the protective film patch. 7. Use the solution to liberally spray the adhesive side of the protective patch, the mounting location along with your hands. 8. Position the paint protective film patch to the desired location on the vehicle. 9. Spray the surface of the film with the alcohol, water and soap solution. 10. Using a dampened squeegee, start at the center of the protective patch, working outward in order to remove the air and solution from under the protective patch. 11. Release any air bubbles with a pin. 12. Dry the surface with a clean, lint-free cotton cloth. Page 9888 Page 246 Fuse Block - Rear X2 Page 3399 Note: The fuel injector assembly is stamped with a part number identification. Be sure to use the correct part number when ordering replacement fuel injectors. 1. Lubricate the NEW fuel injector O-rings with clean engine oil. 2. Install the NEW fuel injector upper O-ring (2). 3. Install the NEW fuel injector lower O-ring (4). 4. Install the fuel injector (3) to the fuel rail. 5. Install the fuel injector retainer (1). 6. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (See: Fuel Rail/Service and Repair). Page 282 Body Control Module (BCM) X3 Page 6901 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the power steering hose bracket and nut (1, 2). Tighten the nut to 5 Nm (45 lb in). 4. Compress the power steering reservoir inlet hose clamp (1) and connect the power steering reservoir inlet hose to the power steering fluid reservoir. 5. Clean any excess power steering fluid from the vehicle and remove the drain pans. 6. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). 7. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure 1. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 2. Disconnect the electrical connector from the park brake warning lamp switch. 3. Remove the park brake warning lamp switch screw (3). 4. Remove the park brake warning lamp switch (2) from the park brake pedal assembly (1). Installation Procedure Page 10094 Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Page 10518 Fog/Driving Lamp Switch: Diagrams Component Connector End Views Fog Lamp Switch (T96) Page 2079 Auxiliary Water Pump: Service and Repair Heater Coolant Pump Replacement Page 6213 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4967 Installation Procedure 1. Clean the sealing surface of the BPMV with denatured alcohol and a clean shop cloth. 2. Carefully install the EBCM (1) to the BPMV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 4 EBCM bolts (1). Tighten the bolts in a cross pattern to 3 Nm (27 lb in). Note: Ensure the electrical connector is correctly inserted into the EBCM prior to placing the locking lever into position. Failure to make a proper connection may cause communication problems with the module. 4. Connect the electrical connector to the EBCM. 5. If installing a new EBCM, it is necessary to program the EBCM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Page 10028 Page 9114 Page 10246 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service Page 5827 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 9486 Page 8417 Disclaimer Page 2855 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 9099 Page 4180 1. Install the shift knob (1) from the shift control. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the shift knob retaining screw (3) and tighten to 4 Nm (35 lb in). 3. Install the boot (2) to the console. Transmission Control Replacement Transmission Control Replacement Removal Procedure 1. Set the park brake and chock the wheels. 2. Remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 3. Disconnect the transmission range selector lever cable terminal (2) from the shift lever pin (3). 4. Release the transmission range selector lever cable retainer (1) and remove the transmission range selector cable from the transmission control lever base (4). Page 9463 Page 1393 Page 6320 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY7 or LZ4 or LZE) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LY7 or LZ4 or LZE) Page 5192 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Page 4329 1. Make sure the checkballs (1-7) are in the proper locations on the channel plate. Retain the checkballs with petroleum jelly. 2. Install a new spacer plate assembly (90) onto the channel plate. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Hand start the spacer plate support bolts (20) and install the spacer plate support (21). Tighten the spacer plate support bolts to 14 Nm (10 lb ft). Page 7696 12. Remove the HVAC module assembly (1). Installation Procedure 1. Install the HVAC module assembly (1). Page 6446 Wheel Speed Sensor (WSS) - Left Rear Wheel Speed Sensor (WSS) - Right Front Page 1568 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 7818 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Page 10050 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Page 3191 Throttle Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 1814 4. Remove the heater cord (1). Installation Procedure 1. Install the heater cord (1). Page 3103 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor - Bank 1 Exhaust (LY7) Camshaft Position (CMP) Sensor - Bank 1 Intake (LY7) Page 9428 Seat Back: Service and Repair Driver or Passenger Seat Back Cushion Cover and Pad Replacement Driver or Passenger Seat Back Cushion Cover and Pad Replacement Page 10801 Wiper Motor: Service and Repair Windshield Wiper System Module Replacement Windshield Wiper System Module Replacement Removal Procedure Note: The new wiper drive system module does not include the wiper motor nor the motor support bracket. You must install the old components to the new wiper system module. 1. Remove the wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper Arm/Service and Repair). 2. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Air Inlet Grille Panel Replacement). 3. Remove the bolts (1) attaching the wiper module to the plenum. 4. Carefully lift the wiper module out of the plenum. 5. Disconnect the electrical connector from the wiper motor. 6. Remove the wiper module assembly (2) from the vehicle. Page 7010 12. Remove the power steering gear outlet hose retainer from the right side rear of the frame. 13. Remove the steering gear bolts, nuts, and washers from the steering gear. 14. Rotate the steering gear as necessary in order to remove the steering gear through the left front wheel opening. 15. Transfer any parts as necessary. Installation Procedure 1. Install the steering gear through the left front wheel opening. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Start all of the bolts and nuts by hand before finalizing any torques. 2. Install the steering gear bolts, nuts, and washers to the steering gear and tighten to 110 Nm (81 lb ft). 3. Install the power steering gear outlet hose retainer to the right side rear of the frame. Page 2763 Engine Control Module (ECM) X2 (LY7) Page 5013 Page 3897 Control Module: Service and Repair Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/6T70/6T75 Automatic Transmission/Control Valve Body Cover Replacement). 2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3). 5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring (8) to the side. Spring will be released with the removal of the control valve body assembly. 7. Remove the 2 control valve body bolts (4) M6 x 65. Page 7931 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the SIR circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Page 4335 9. Remove the oil cooler inlet and outlet hoses from the retainer on the control valve body cover. 10. Remove the 2 control valve body cover studs M6 x 30. 11. Remove the 9 lower control valve body cover bolts M6 x 30. 12. Lower the vehicle. 13. Remove the air cleaner outlet duct. 14. Disconnect the transmission wire harness retainer from the bracket on top of the transmission. 15. Remove the top 3 control valve body cover bolts M6 x 30. 16. Remove the control valve body cover. 17. Remove the control valve body cover gasket. Caution: Support the control solenoid valve assembly around the connector when removing the seal. Excessive pulling force can damage the internal electrical connections. 18. Remove the control valve body cover wiring connector hole seal. 19. Remove all traces of the old gasket material. Clean the transmission case and control valve body cover gasket surfaces. Page 1740 1. Lubricate the solenoid valve O-ring seals with clean engine oil. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the intake (2) CMP actuator solenoid valve and bolt, if required. Tighten the bolt to 10 Nm (89 lb in). 3. Install the exhaust (1) CMP actuator solenoid valve and bolt, if required. Tighten the bolt to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (2) to the intake CMP actuator solenoid valve (3), if required. 5. Connect the engine wiring harness electrical connector (1) to the exhaust CMP actuator solenoid valve (4), if required. 6. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 4454 Radiator Inlet Hose Replacement Radiator Hose: Service and Repair Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement Page 7867 Specifications Water Pump: Specifications Water Pump Bolts ................................................................................................................................ ........................................................ 25 Nm (18 lb ft) Secondary Air Injection Pump Hose Replacement Air Injection Hose/Tube: Service and Repair Secondary Air Injection Pump Hose Replacement Secondary Air Injection Pump Hose Replacement Removal Procedure 1. Disconnect the secondary air injection pump hose (1) from the secondary air injection pump. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) 2. Disconnect the secondary air injection pump hose (1) from the secondary air injection check valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) 3. Remove the secondary air injection pipe from the vehicle. Installation Procedure Page 237 Fuse Block - Underhood X4 Page 1890 5. Install the knock sensor electrical connector lead (1) to the oil level indicator tube bracket (2). 6. Install the engine wiring harness clip (1) to the oil level indicator tube bracket (2). 7. Lower the vehicle. 8. Install the engine wiring harness clip (1) to the oil level indicator tube bracket (2). 9. Install the oil level indicator. 10. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Service and Repair Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement Page 342 Page 5975 Page 1456 Page 457 Control Module: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 5393 Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake (LY7) Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust (LY7) Page 9958 Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 5582 Speaker - Left Rear (UQ3) Speaker - Left Rear (UW5) Page 149 Page 837 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 3. Reposition the EVAP canister purge tube (1) out of the way. 4. Disconnect the fuel injector wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor. Page 9677 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 7703 Refrigerant: Fluid Type Specifications Refrigerant ........................................................................................................................................... ....................................................................... R-134a Page 6912 6. Remove the 2 power steering gear outlet pipe hose retainers (1) from the right side of the front frame. 7. Remove the 2 power steering gear outlet hose retainers from the front of the front frame. 8. Remove the steering gear. Refer to Steering Gear Replacement (See: Steering Gear/Service and Repair/Steering Gear Replacement). Page 2181 lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If reinstalling the original sensor, or if installing a NEW sensor without a sealer, coat the threads with sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor (1) to the thermostat housing and tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). Page 5327 Diagram Information and Instructions Keyless Entry Transmitter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Page 10464 OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 8436 Disclaimer Page 9080 Page 226 Fuse Block - Underhood Top View (LAT) Page 9536 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Delphi Connectors Delphi Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 10157 For vehicles repaired under warranty use the table above. Disclaimer Page 9350 4. Install the actuator screw (1) to the window track (2) and tighten to 2 Nm (18 lb in). 5. Power the sunroof window tracks to the close position. 6. Install sunroof window. Refer to Sunroof Window Replacement (See: Sunroof / Moonroof Panel/Service and Repair). 7. Verify that the spring action of the sunroof air deflector is operating. 8. Close the sunroof window. Page 4977 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Service Precautions Catalytic Converter: Service Precautions Three-Way Catalytic Converter Damage Caution Caution: In order to avoid damaging the replacement three-way catalytic converter, correct the engine misfire or mechanical fault before replacing the three-way catalytic converter. Page 7654 Heater Hose: Service and Repair Heater Outlet Hose Replacement - Connector to Engine Heater Outlet Hose Replacement - Connector to Engine Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic HVAC Control Module Replacement HVAC Control Module Replacement Blower Motor Control Processor Replacement Blower Motor Control Processor Replacement Page 6968 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become UN-centered and cause possible damage to the SIR coil. If you think the SIR coil has became UN-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Page 4507 25 - Torque Converter and Support and A/Trans Fluid Pump Housing Assembly 26 - Torque Converter and Differential Housing Bolt 27 - Torque Converter Assembly 28 - Dust Cover Push Pin - Model Dependent 29 - Dust Cover Bolt - Model Dependent 30 - Dust Cover - Model Dependent 31 - Front Differential Carrier Assembly 32 - Input Shaft Thrust Bearing Assembly 33 - A/Trans Case Cover Gasket 34 - A/Trans Case Cover Assembly 35 - A/Trans Case Cover Assembly Bolt A/Trans Case Cover, 2-6 and Low Reverse Pistons 400 - A/Trans Input Speed Sensor Assembly 401 - A/Trans Input Speed Sensor Bolt 402 - ISS O-Ring Seal 403 - A/Trans Case Cover Assembly 404 - 3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring 405 - 2-6 Clutch Piston 406 - 2-6 Clutch Spring Assembly 407 - 2-6 Clutch Spring Retainer Ring 408 - Low and Reverse Clutch Piston Assembly 409 - Low and Reverse Clutch Spring 410 Low and Reverse Clutch Spring Retainer Ring Page 5193 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Page 6274 Engine Control Module (ECM) X2 (LAT) Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Front and Right Side of the Engine Components (LY7) Page 9356 Installation Procedure 1. Install the hose to the vehicle 2. Pull the hose out through the hole in the front hinge pillar. 3. Install the grommet onto the end of the hose. 4. Install the grommet into the hole in the front hinge pillar. 5. Connect the hose to the attachments on the windshield pillar. 6. Connect the front sunroof drain hose to the sunroof drain spigot. 7. Install the headliner. Refer to Headlining Trim Panel Replacement (See: Interior Moulding / Trim/Headliner/Service and Repair). 8. Inspect sunroof for proper operation. Sunroof Housing Rear Drain Hose Replacement Sunroof Housing Rear Drain Hose Replacement Page 10047 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Page 4896 8. Connect the master cylinder primary brake pipe fitting (1) and tighten to 32 Nm (24 lb ft). 9. Connect the left brake pipe fitting (1) and tighten to 20 Nm (15 lb ft). Page 889 1. Install the MAF/IAT sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1) and tighten to 2.5 Nm (22 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor (2). Page 9102 Page 4898 12. Connect the right front brake pipe fitting (1) and tighten to 20 Nm (15 lb ft). Note: Ensure the electrical connector is correctly inserted into the EBCM prior to placing the locking lever into position. Failure to make a proper connection may cause communication problems with the module. 13. Connect the EBCM electrical connector. 14. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding). Note: Place the ignition switch in the ON position. Do not start the engine. 15. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). 16. Observe the feel of the brake pedal after performing the diagnostic system check. If the pedal now feels spongy, air may have been in the secondary circuit of the brake modulator assembly, which may have been introduced into the primary circuit. If the pedal feels spongy, perform the Antilock Brake System Automated Bleed (See: Brake Bleeding/Service and Repair/Antilock Brake System Automated Bleed). Page 6387 Radio Antenna Module Page 2816 Campaign - Service Air Bag Message, Replace Connectors Technical Service Bulletin # 11034 Date: 110314 Campaign - Service Air Bag Message, Replace Connectors CUSTOMER SATISFACTION Bulletin No.: 11034 Date: March 14, 2011 Subject: 11034 - Service Air Bag Message - Replace Connectors Models: 2010 Chevrolet Malibu 2010 Pontiac G6 Some, but not all, of the vehicles involved in this Program were also involved in Customer Satisfaction Program (CSP) 10085. These vehicles are to be inspected to determine if the repair for CSP 10085 included the replacement of the two connectors. If the connectors were replaced, no further action is required on these vehicles. If they were not replaced, dealers are to install the new connectors. Condition Certain 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may have a condition in which wear could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact airbag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG system warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG system DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Some of these vehicles were previously repaired under Customer Satisfaction Program 10085. These vehicles had the wire harness secured, and in some cases, rerouted. They did not require the installation of the two connectors. However, there have been reports of the SERVICE AIR BAG message illuminating in the Driver Information Center after the repair, due to movement of the connector between the body main wiring harness and the front driver and passenger side impact air bag. With this Customer Satisfaction Program, dealers will install the two new connectors. Correction Dealers are to inspect and, if necessary, replace the front seat-mounted side impact air bag connectors. Vehicles Involved Involved are certain 2010 model year Chevrolet Malibu and Pontiac G6 vehicles. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty Management system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Page 8006 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 7915 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. Page 1744 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gauge at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Page 1242 3. Install the heater outlet hose to the heater core. 4. Reposition the heater outlet hose clamp at the heater core using the J 38185. 5. Install the surge tank to the surge tank bracket. 6. Fill the coolant. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement). 3. Remove the pressure relief valve from under vehicle, behind rear fascia. Installation Procedure 1. Install the pressure relief valve. 2. Install the rear fascia. Refer to Rear Bumper Fascia Replacement (See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement). Page 7651 5. Reposition the heater outlet hose clamp at the engine using the J 38185. 6. Remove the heater outlet hose from the engine. Installation Procedure 1. Install the heater outlet hose to the engine. 2. Reposition the heater outlet hose clamp at the engine using the J 38185. Page 8102 1 - Outside Rearview Mirror - Passenger 2 - Door Frame 3 - Door Latch - Passenger 4 - Inflatable Restraint Side Impact Sensor (SIS) - Right 5 - Window Switch - Passenger 6 - Speaker - Right Front 7 - Window Motor - Passenger 8 - Door Lock Switch - Passenger 9 - Courtesy Lamp - Right Front Door Page 5683 X207 Inline Harness Connector End Views X207 I/P Harness to Body Harness Page 5756 Fuse Block - Rear Bottom View Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Page 6499 Page 6011 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Page 3064 Page 6023 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Page 3373 2. Place the container on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. 3. Observe the fuel sample. If any physical contaminants or water are present, clean the fuel system. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Fuel System Cleaning (See: Service and Repair) Page 8196 Page 1933 1. Install new piston oil nozzles. Turn the extension by hand to ensure that the threads are aligned. Use a long screwdriver to ensure that the nozzle does not rotate and make sure that the locating pin is properly indexed in its hole. Tighten the piston oil nozzle bolts to 15 Nm (11 lb ft). 2. Install the engine oil pan. Refer to Oil Pan Replacement (See: Oil Pan/Service and Repair). 3. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Replace the oil filter and fill the engine with new engine oil. Refer to Engine Mechanical Specifications (See: Specifications/Service Limits & General Specifications). 5. Reset the engine oil life monitor. Refer to GM Oil Life System Resetting (See: Instrument Panel, Gauges and Warning Indicators/Oil Change Reminder Lamp/Service and Repair). Locations Backup Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 780 Camshaft Position (CMP) Sensor - Bank 2 Intake (LY7) Page 8742 Page 7392 Wheels: Description and Operation Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely corroded. Note: Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Warning If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Caution: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Aluminum wheel identification is cast into the inboard side of the wheel. Page 5244 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Page 1066 Window Switch - Right Rear Page 5459 Engine Coolant Temperature (ECT) Sensor (LAT or LE5 or LE9) Page 5253 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Page 2797 Page 6071 same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 8365 Digital Video Disc (DVD) Display - Passenger Seat Headrest X2 (SPO Accessory) (UJ5) Body - Stain/Film On Windshield Glass Perimeter Windshield: All Technical Service Bulletins Body - Stain/Film On Windshield Glass Perimeter TECHNICAL Bulletin No.: 09-08-48-006 Date: September 18, 2009 Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Condition Some customers may comment on a clear stain or film on the inside of the windshield glass. This condition appears along the outer edges of the glass along the top, bottom or A-pillar areas. Normal glass cleaning procedures will not remove the stain. Cause The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries, it may appear to have etched the glass. Correction Note A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less satisfactory results. Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of the windshield glass. After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm water. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. A/T Controls - Downshift Hesitation/Delayed Shifting PROM - Programmable Read Only Memory: Customer Interest A/T Controls - Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 4136 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Component Location Component Location Component Locations 1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid Pump Drive Link Assembly 12 - Park Pawl Page 10167 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 10124 Cigarette Lighter: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Special Tools J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. The J 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. Page 3384 Fuel Injector: Pressure, Vacuum and Temperature Specifications If the difference between any individual pressure drop and the average pressure drop is more than 20 kPa (3 psi), replace the fuel injector. TPMS System - Service And Re-Learning Sensor IDs Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Brake Fluid Effects on Paint and Electrical Components Caution Paint: Service Precautions Brake Fluid Effects on Paint and Electrical Components Caution Brake Fluid Effects on Paint and Electrical Components Caution Caution: Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid. Page 2476 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 3. Reposition the EVAP canister purge tube (1) out of the way. 4. Disconnect the fuel injector wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor. Locations Fog/Driving Lamp Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 6266 Engine Control Module (ECM) X1 (LAT) Page 5306 Fuse 6 .................................................................................................................................................. ................................................................ Emission Fuse 7 ................................................................. ...................................................................................................................... Left Headlamp Low-Beam Fuse 8 ............................................................................................................................... .......................................................................................... Horn Fuse 9 .............................................. ...................................................................................................................................... Right Headlamp Low-Beam Fuse 10 ............................................................................................................ ........................................................................................ Front Fog Lamps Fuse 11 .......................... .......................................................................................................................................................... Left Headlamp High-Beam Fuse 12 .................................................................................................... .............................................................................. Right Headlamp High-Beam Fuse 13 ................... ........................................................................................................................................................... Engine Control Module BATT Fuse 14 ................................................................................................ .................................................................................................. Windshield Wiper Fuse 15 ................ ............................................................................................................................................................. Antilock Brake System (IGN 1) Fuse 16 .............................................................................................. ................................................................................ Engine Control Module IGN 1 Fuse 17 ............... .............................................................................................................................................................. ........................... Cooling Fan 1 Fuse 18 ............................................................................................ ............................................................................................................ Cooling Fan 2 Fuse 19 .................................................................................................................................. Run Relay, Heating, Ventilation, Air Conditioning Blower Fuse 20 ........................................................................ ................................................................................................................. Body Control Module 1 Fuse 21 ................................................................................................................................................ .......................... Body Control Module Run/Crank Fuse 22 ................................................................ ......................................................................................................................... Rear Electrical Center 1 Fuse 23 ............................................................................................................................................. ............................................ Rear Electrical Center 2 Fuse 24 ........................................................... ............................................................................................................................... Antilock Brake System Fuse 25 ................................................................................................................................... ...................................................... Body Control Module 2 Fuse 26 ................................................... .............................................................................................................................................................. ... Starter Fuse 41 ................................................................................................................................ ......................................................... Electric Power Steering Fuse 42 ............................................... .................................................................................................................... Transmission Control Module Battery Fuse 43 .................................................................................................. Ignition Module (LZ4, LZE, LE9 & LE5); Injectors, Ignition Coils Odd (LY7) Fuse 44 ............................................................................................................. Injectors (LZ4, LZE, LE9 & LE5); Injectors, Ignition Coils Even (LY7) Fuse 45 .................................................................................................................................................... Post Cat 02 Sensor Heaters (LY7, LZ4 & LZE) Fuse 46 ............................................................................. .......................................................................................................... Daytime Running Lamps Fuse 47 ......................................................................................................................................................... ................... Center High-Mounted Stoplamp Fuse 50 ........................................................................ ................................................................................................................... Driver Power Window Fuse 51 ................................................................................................................................................ ................................................................ Not Used Fuse 52 ............................................................... .......................................................................................................................................... AIR Solenoid Fuse 54 ................................................................................................................................. ................................................... Regulated Voltage Control Fuse 55 ................................................ ..................................................................................................................................................... DC/AC Inverter Fuse 56 ...................................................................................................................... ......................................................... Antilock Brake System BATT Relays .................................................................................................................................................. ........................................................................ Usage Relay 28 .............................................................................................................................................. ......................................................... Cooling Fan 1 Relay 29 ............................................................. ..................................................................................................................... Cooling Fan Series/Parallel Relay 30 ...................................................................................................................... ................................................................................. Cooling Fan 2 Relay 31 ..................................... .............................................................................................................................................................. ................ Starter Relay 32 .................................................................................................................. ............................................................................ Run/Crank, Ignition Relay 33 .................................. .............................................................................................................................................................. ............ Powertrain Relay 34 ............................................................................................................... ........................................................................ Air Conditioning Clutch Relay 35 ................................ .............................................................................................................................................................. ............. High Beam Relay 36 .............................................................................................................. .................................................................................... Front Fog Lamps Relay 37 ............................. .............................................................................................................................................................. .......................... Horn Relay 38 ........................................................................................................... ............................................................................... Low-Beam Headlamp Relay 39 ........................... .............................................................................................................................................................. .... Windshield Wiper 1 Relay 40 ......................................................................................................... .................................................................................... Windshield Wiper 2 Relay 48 ......................... ............................................................................................................................................................. Daytime Running Lamps Relay 49 ...................................................................................................... ....................................................................................................... Stoplamps Relay 53 .................... .............................................................................................................................................................. ..................... AIR Solenoid Diodes ................................................................................................................................................. ......................................................................... Usage Relay 27 .............................................................................................................................................. ..................................................................... Wiper Heated Oxygen Sensor Replacement - Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 1 Heated Oxygen Sensor Replacement - Sensor 1 Page 2129 7. Remove the heater core. Installation Procedure 1. Install the heater core. Page 9063 Disclaimer Page 9434 3. Remove the staples from the seat back cover. 4. Remove the seat back cover from the pad. Installation Procedure 1. Install the seat back cover to the pad. 2. Staple the seat back cover to the seat back. 3. Install the rear seat back. Refer to Rear Seat Back Cushion Replacement (See: Rear Seat Back Cushion Replacement). 4. Install the rear seat head restraints. Refer to Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat Head Restraint Replacement). Rear Seat Back Cushion Frame Replacement Rear Seat Back Cushion Frame Replacement Removal Procedure Locations Transmission Position Switch/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components (ME7 or MN5) 1 - Park/Neutral Position (PNP) Switch Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) Page 6770 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. Page 2338 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 6360 Inflatable Restraint Steering Wheel Module X1 Inflatable Restraint Steering Wheel Module X2 Service and Repair Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement Removal Procedure 1. Remove the fuel pump module assembly. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor electrical connector (1). 3. Disengage the locking tab (2) on the fuel level sensor by pushing inward. 4. Remove the fuel level sensor (1) from the alignment feature (2). Installation Procedure Page 4456 Transmission Control Module (TCM) (MN5 with LZ4 or LZE) Page 147 Page 745 Hazard Warning Switch: Service and Repair Hazard Warning Switch Replacement Page 4948 14. Install the vacuum check valve (1) to the vacuum brake booster grommet. If necessary, a small amount of denatured alcohol may be used as a lubricant for assembly. Do not use soap. 15. Connect the LF brake pipe fitting (1) and tighten to 20 Nm (15 lb ft). Blower Motor Resistor Replacement Blower Motor Resistor: Service and Repair Blower Motor Resistor Replacement Blower Motor Resistor Replacement Page 9139 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Page 7903 * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Courtesy Transporation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the actual cost of the woven polyester electrical tape required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the involved vehicle listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your facility for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Page 9077 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Page 9200 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 581 3. Using needle nose pliers carefully depress the retaining tabs on the end of the brake fluid level sensor. 4. Remove the brake fluid level sensor from the master cylinder. Installation Procedure Page 6503 X102 Right Front Wheel Speed Sensor Harness to Body Harness X108 Inline Harness Connector End Views X108 Engine Harness to Body Harness (LAT) Page 5740 Fuse Block - Underhood Top View (LAT) Service and Repair Power Steering Bleeding: Service and Repair Power Steering System Bleeding Important: * Use clean, new power steering fluid type only. See the Maintenance and Lubrication subsection for fluid specifications. Refer to Fluid and Lubricant Recommendations (See: Maintenance). * Hoses touching the frame, body or engine may cause system noise. Verify that the hoses do not touch any other part of the vehicle. * Loose connections may not leak, but could allow air into the steering system. Verify that all hose connections are tight. Important: Power steering fluid level must be maintained throughout bleed procedure. 1. Fill pump reservoir with fluid to minimum system level, FULL COLD level, or middle of hash mark on cap stick fluid level indicator. Important: With hydro-boost only, the oil level will appear falsely high if the hydro-boost accumulator is not fully charged. Do not apply the brake pedal with the engine OFF. This will discharge the hydro-boost accumulator. 2. If equipped with hydro-boost, fully charge the hydro-boost accumulator using the following procedure: 1. Start the engine. 2. Firmly apply the brake pedal 10-15 times. 3. Turn the engine OFF. 3. Raise the vehicle until the front wheels are off the ground. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 4. Key on engine OFF, turn the steering wheel from stop to stop 12 times. Vehicles equipped with hydro-boost systems or longer length power steering hoses may require turns up to 15 to 20 stop to stops. 5. Verify power steering fluid level per operating specification. Refer to Checking and Adding Power Steering Fluid (See: Service and Repair/Checking and Adding Power Steering Fluid). 6. Start the engine. Rotate steering wheel from left to right. Check for sign of cavitation or fluid aeration (pump noise/whining). 7. Verify the fluid level. Repeat the bleed procedure, if necessary. Power Steering Fluid Reservoir Inlet Hose Replacement Power Steering Line/Hose: Service and Repair Power Steering Fluid Reservoir Inlet Hose Replacement Power Steering Fluid Reservoir Inlet Hose Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). 2. Remove as much power steering fluid from the power steering fluid reservoir as possible. 3. Place drain pans under the vehicle as needed. 4. Compress the power steering reservoir inlet hose clamp (1) and disconnect the power steering reservoir inlet hose from the power steering fluid reservoir. 5. Remove the power steering hose bracket and nut (1, 2). Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 6954 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become UN-centered and cause possible damage to the SIR coil. If you think the SIR coil has became UN-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. A/T Controls - Downshift Hesitation/Delayed Shifting Control Module: Customer Interest A/T Controls - Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9178 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 8092 13. Connect the appropriate pigtail adapter (2) to the SIR deployment harness (1). 14. Extend the SIR deployment harness and adapter to full length from the deployment fixture. 15. Connect the seat belt pretensioner connector to the adapter on the deployment harness. Note: When deploying a seat belt retractor pretensioner, the rapid expansion of gas is very loud. Notify the people in the immediate area that a seat belt pretensioner will be deployed. 16. Clear the area of people. 17. Separate the 2 banana plugs on the SIR deployment harness. Page 10015 Page 4988 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Page 2478 1. Lubricate the NEW MAP sensor seal with clean engine oil. 2. Install the MAP sensor (1) into the intake manifold. 3. Connect the fuel injector wiring harness electrical connector (2) to the number 3 fuel injector. 4. Install the fuel injector wiring harness clips (1) to the fuel rail tabs. Page 2363 Engine Control Module (ECM) X3 (LAT) Page 4540 Shift Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH2) Page 5687 X300 Inline Harness Connector End Views X300 Body Harness to Driver Seat Harness Page 10318 For vehicles repaired under warranty use the table above. Disclaimer Page 349 * Evaporative emission (EVAP) system losses Should this vehicles on-board diagnostic system (ECM) detect a condition that could result in excessive emissions, the ECM turns ON the malfunction indicator lamp (MIL) and stores a DTC that is associated with the condition. Aftermarket (Add-On) Electrical And Vacuum Equipment Caution: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems. Caution: Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle. Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicles electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment. Add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include equipment not connected to the vehicle electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain condition is to eliminate all of the aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, the problem may be diagnosed in the normal manner. Electrostatic Discharge (ESD) Damage Note: In order to prevent possible electrostatic discharge damage to the engine control module (ECM), DO NOT touch the connector pins on the ECM. The electronic components that are used in the control systems are often designed to carry very low voltage. The electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 V of static electricity can cause damage to some electronic components. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore, it is important to use care when handling and testing electronic components. Emissions Control Information Label The underhood Vehicle Emissions Control Information Label contains important emission specifications and setting procedures. In the upper right corner is the exhaust emission information. This identifies the year, the manufacturing division of the engine, the displacement of the engine in liters, the class of the vehicle, and type of fuel metering system. There is also an illustrated emission components and vacuum hose schematic. This label is located in the engine compartment of every General Motors vehicle. If the label has been removed, it can be ordered from GM service parts operations (GMSPO). Underhood Inspection Note: This inspection is very important and must be done carefully and thoroughly. Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a condition without further steps. Use the following guidelines when performing an inspection: * Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects. * Inspect any hoses that are difficult to see. * Inspect all of the wires in the engine compartment for the following conditions: - Burned or chafed spots - Pinched wires - Contact with sharp edges - Contact with hot exhaust manifolds Page 3102 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 2. Remove the engine cover, if required. 3. Remove the fuel rail service port cap. 4. Wrap a shop towel around the fuel rail service port and using a small flat bladed tool, depress (open) the fuel rail test port valve. 5. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 6. Install the fuel rail service port cap. 7. Install the engine cover, if required. 8. Tighten the fuel fill cap. Page 5165 Page 8989 Front Floor Console Rear Cover Replacement Roof Console Replacement Roof Console Replacement Page 9046 Page 7352 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Locations Camshaft Position Sensor: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch Page 6678 "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN(s) 19118426 and 20968489 will not be eligible for RIM management. * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Service Procedure Replace Wire Harness Connector 2010 Chevrolet Malibu and 2010 Pontiac G6 Tools Required - J 38125-7 Crimp Tool - J 38125-6 Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Seat shown out-of-vehicle for illustration purposed Page 7664 Hose/Line HVAC: Service and Repair Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 2. Remove the refrigerant pressure sensor wire harness connector. 3. Remove the refrigerant pressure sensor. 4. Remove the liquid line bracket bolt. 5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 6. Remove the surge tank from the surge tank bracket. 7. Remove the suction hose and liquid line nut from the thermal expansion valve (TXV). 8. Remove the suction hose and liquid line from the TXV. Page 5715 X801 Inline Harness Connector End Views X801 Right Rear Door Harness to Right Rear Door Trim Pad Harness X900 - X999 Inline Harness Connector End Views Page 7403 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the wheel bearing/hub mounting bolts (1) and tighten to 115 Nm (85 lb ft). Page 9455 Seat Cushion: Service and Repair Seat Cushion Inner Trim Panel Replacement Seat Cushion Inner Trim Panel Replacement Page 9611 Service and Repair Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid Filter and Seal Replacement Removal Procedure Warning Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. 1. Position the vehicle on a hoist and raise the vehicle. 2. Place a drain pan under the transaxle oil pan. 3. Remove the oil pan bolts from the front and sides only. 4. Loosen the rear oil pan bolts approximately 4 times. Caution: Pry the oil pan carefully in order to prevent damage to the transaxle case or the oil pan sealing surfaces. 5. Lightly tap the oil pan with a rubber mallet or carefully pry in order to allow the oil to drain. 6. Remove the AIR. Refer to Transmission Fluid Level and Condition Check (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic Procedures/4T45-E Automatic Transmission/Transmission Fluid Level and Condition Check). 7. Inspect the fluid color. Page 4109 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt (2) M6 x 23. 4. Remove the input speed sensor (3). 5. Remove the 3 input speed sensor seals (1). Installation Procedure Page 9364 3. Using the access hole in the sunroof module cross bar, install the push-pin fastener which secures the rear sunroof water gutter to the roof. 4. Install the sunroof motor/actuator bolts to the base of the sunroof module and tighten to 2 Nm (18 lb in). 5. Connect the front and rear drain hoses to the drain spigots. 6. Install the sunshade. Refer to Sunroof Sunshade Replacement (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement) Page 1584 Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Page 3845 1 - Control Solenoid Valve Assembly (with Transmission Control Module) Page 3176 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY7 or LZ4 or LZE) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LY7 or LZ4 or LZE) Page 480 Procedures Tires: Procedures Tire Repair Tire Repair Warning * Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. * Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. * NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. * NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Note: * NEVER repair tires worn to the tread indicators 1.59 mm (2/32 in) remaining depth. * NEVER repair tires with a tread puncture larger than 6.35 mm (1/4 in). * NEVER substitute an inner tube for a permissible or non-permissible repair. * NEVER perform an outside-in tire repair (plug only, on the wheel). * Every tire must be removed from the wheel for proper inspection and repair. * Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. * Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection Page 2858 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Bosch Connectors Bosch Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 1451 Page 8274 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close Page 5958 For vehicles repaired under warranty, use the table. Disclaimer Page 6724 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 5066 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (See: Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). 2. Ensure that the location measurement of the battery current sensor was recorded for reference during installation. 3. Squeeze the ground ends of the negative battery cable together and remove the sensor (1) from the cable. Installation Procedure Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 1. Install the battery current sensor (1) by passing the ground ends of the negative battery cable through the sensor. Page 8239 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 2664 Body Control Module (BCM) X4 Page 3409 8. This step applies to the Push down TI style connectors ONLY. Release the fitting by pressing on the tabs indicated by the arrow. Quick Connect Fittings 9. Pull the connection apart. 10. Wipe off the male pipe end using a clean shop towel. 11. Inspect both ends of the fitting for dirt and burrs. 12. Clean or replace the components as required. Installation Procedure 1. Apply a few drops of clean engine oil to the male connection end. Page 8195 Page 2831 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Page 6967 1. Slide the steering wheel position sensor into place and remove the locating pin. 2. Connect any electrical connectors as needed. 3. Connect the intermediate steering shaft to the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 4. Remove anti-rotation pin J 42640. Page 6644 Your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle not only meets, but exceeds government standards for side impact protection. GM recently introduced into production, changes that add to that protection. At no charge, your dealer will make similar changes to your vehicle, which was built before the production change. What We Will Do: To enhance the side impact protection, your GM dealer will update the wiring harness for both front seat side impact airbags. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 10085 Page 1149 1. Install a NEW air filter assembly. 2. Close the air cleaner cover. 3. Engage the air cleaner cover latches (1). 4. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 5. Install the air cleaner outlet duct to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Tighten the air cleaner outlet duct clamp at the air cleaner assembly to 4 Nm (35 lb in). Page 10361 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2674 Camshaft Position (CMP) Sensor - Bank 2 Intake (LY7) Page 4720 3. Install the 2 brake pedal assembly to cowl mounting nuts and tighten to 15 Nm (11 lb ft). 4. Connect the brake pedal pushrod retaining clip (1) the wave washers (2) and the brake booster pushrod (3) to the brake pedal pin (4). 5. Install the steering column assembly to the vehicle. Refer to Steering Column Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Replacement). 6. Connect the electrical connector to the brake apply sensor. 7. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 8. Install the knee bolster. Refer to Driver Knee Bolster Panel Replacement (See: Restraint Systems/Knee Diverter/Service and Repair). 9. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration (See: Accessories and Optional Equipment/Pedal Positioning System/Pedal Positioning Sensor/Service and Repair/Brake Pedal Position Sensor Calibration). Locations Tail Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 9546 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 10021 Page 9674 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 4900 1. Install the bracket (1) to the BPMV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the BPMV bolt (1) and tighten to 10 Nm (89 lb in). 3. Install the BPMV. Refer to Brake Pressure Modulator Valve Replacement (See: Brake Pressure Modulator Valve Replacement). Page 6267 Page 7081 5. Install the park brake cable retaining clip (2) to the trailing arm bracket (1). 6. Install the park brake cable retaining bracket (1) and the bolt (3) to the trailing arm (2). Tighten the mounting bolt to 10 Nm (89 lb in). 7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 8. Lower the vehicle. Page 552 Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster and Recliner Switch Replacement Driver or Passenger Seat Adjuster and Recliner Switch Replacement Page 9718 Seat Heater: Testing and Inspection Heated Seat Inoperative Heated Seat Inoperative Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description Battery positive voltage is supplied at all times to the heated seat module through the HTD SEAT fuse located in the rear fuse block. When commanded ON, the heated seat module uses this voltage to heat the seat heating elements. Ignition voltage is supplied to the heated seat switch and the heated seat module from the ROOF/HEAT SEAT fuse located in the BCM. The heated seat module and the seat heating elements are grounded through the module ground circuit to G303. Each time the heated seat switch is pressed, ignition voltage is applied through the heated seat signal circuit to the heated seat module. The module counts these inputs to determine what level of heat the vehicle operator is commanding. In response to these switch signals, the heated seat module applies battery voltage and ground through the seat heater element control circuits to the seat heating elements. When the desired seat temperature has been reached, the module will open and close the supply voltage to the heater elements as necessary in order to maintain the seat temperature. Reference Information Schematic Reference Heated/Cooled Seat Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Heated Seats Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Circuit/System Verification Page 6936 Electric Power Steering (EPS) Module X3 (without NVH) Page 1277 2. Ensure the steering gear oil seals (1) are fully seated in the steering gear. Caution: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 3. Install the power steering gear inlet hose to the vehicle. 4. Install the steering gear. Refer to Steering Gear Replacement (See: Steering and Suspension/Steering/Steering Gear/Service and Repair/Steering Gear Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the power steering gear inlet hose (2) to the steering gear and install the power steering gear inlet hose bolt (1). Prior to tightening the power steering gear inlet hose bolt (1), rotate the power steering gear outlet hose clockwise/downwards so it touches the power steering gear inlet hose (2). Verify the power steering hoses are still touching after the power steering gear inlet hose bolt is tight. Tighten the bolt to 27 Nm (20 lb ft). Electrical - Various Electrical Systems Malfunctions Wiring Harness: All Technical Service Bulletins Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Page 5992 Page 10138 Dimmer Switch: Diagrams Component Connector End Views I/P Dimmer Switch Page 5941 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. Page 5572 Seat Horizontal Motor - Driver (AG1 or LTZ) Seat Horizontal Motor - Passenger (LTZ) Page 749 Horn Switch: Service and Repair Steering Wheel Horn Contact Replacement Page 7750 Cabin Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Lower (C68) Air Temperature Sensor - Upper (C68) System Diagnosis Idle Speed: Testing and Inspection Throttle/Idle Learn Description The engine control module (ECM) learns the idle position of the throttle plate to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned. A vehicle that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero. The idle may be unstable or a DTC may set if the learned values do not match the actual airflow. Conditions for Running the Throttle Learn Procedure * DTCs P0101, P0102, P0103, P0107, P0108, P0111, P0112, P0113, P0506, and P0507 are not set. * The engine speed is between 450-4,000 RPM. * The manifold absolute pressure (MAP) is greater than 5 kPa. * The mass air flow (MAF) is greater than 2 g/s. * The ignition 1 voltage is greater than 10 volts. Throttle Learn With Scan Tool-Reset 1. Ignition ON, engine OFF. With a scan tool, perform the Idle Learn Reset in Module Setup. 2. Start the engine, monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation parameter value should equal 0 percent and the engine should be idling at a normal idle speed. ‹› If the engine is not idling normally, proceed with the Learn portion of the diagnostic. 3. Clear the DTCs and return to the diagnostic that referred you here. Without Scan Tool-Learn Important: Do NOT perform the Without Scan Tool-Learn procedure if DTCs are set. Refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle). 1. The engine speed is between 450-4,000 RPM. 2. The manifold absolute pressure (MAP) is greater than 5 kPa. 3. The mass air flow (MAF) is greater than 2 g/s. 4. The ignition 1 voltage is greater than 10 volts. 5. Start and idle the engine in Park for 3 minutes. 6. With a scan tool, monitor desired and actual RPM. 7. The ECM will start to learn the new idle cells and Desired RPM should start to decrease. 8. Ignition OFF for 60 seconds. 9. Start and idle the engine in Park for 3 minutes. Important: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. 10. After the 3 minute run time the engine should be idling normal. ‹› If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles. 11. After the drive cycle, the engine should be idling normally. ‹› If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6. 12. Once the engine speed has returned to normal, clear DTCs. Specifications Engine Oil Pressure: Specifications Oil Pressure Minimum - @1000 RPM @ 90°C (194°F) ........................................................................................................................... 206.84-482.63 kPa (30-70 psi) Page 1004 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service Page 7938 "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN(s) 19118426 and 20968489 will not be eligible for RIM management. * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Service Procedure Replace Wire Harness Connector 2010 Chevrolet Malibu and 2010 Pontiac G6 Tools Required - J 38125-7 Crimp Tool - J 38125-6 Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Seat shown out-of-vehicle for illustration purposed Page 400 Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 1401 Fuse Block - Underhood Top View (LE5 or LE9) Service and Repair Refrigerant Filter: Service and Repair Air Conditioning (AC) Refrigerant Filter Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery and Recharging). 2. Remove the surge tank from the surge tank bracket. 3. Remove the suction hose and liquid line nut from the thermal expansion valve (TXV). 4. Remove the suction hose and liquid line from the TXV. 5. Remove the line clip from the dash. Page 6176 Page 7714 Refrigerant Oil: Fluid Type Specifications PAG Oil GM P/N 12378526 for United States PAG Oil GM P/N 88900060 for Canada Page 7449 Instrument Panel Center Air Outlet Duct Replacement Windshield Defroster Duct Replacement Windshield Defroster Duct Replacement Removal Procedure 1. Remove the instrument panel (I/P) pad. Refer to Instrument Panel Upper Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Upper Trim Panel Replacement). 2. Press on the 2 tabs of the windshield defroster duct. Page 6156 Page 3534 Ignition Coil 3 (LY7) Page 3896 Page 1261 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the liquid line bracket bolt and tighten to 10 Nm (89 lb in). 5. Install the refrigerant pressure sensor wire harness connector. 6. Install the line clip to the dash. 7. Install the suction hose to the dash clip. 8. Install the suction hose and liquid line to the TXV. 9. Install the suction hose and liquid line nut to the TXV and tighten the nut to 20 Nm (15 lb ft). 10. Install new O-rings. Refer to Air Conditioning O-Ring Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning O-Ring Seal Replacement). 11. Install the suction hose to the compressor hose. Page 3893 Transmission Control Module (TCM) (MN5 with LE5 or LE9) Page 787 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Exhaust Camshaft Position Sensor Replacement - Exhaust Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (5) from the exhaust camshaft position (CMP) sensor (4). 3. Remove the CMP sensor bolt. (Intake CMP shown, exhaust CMP similar). 4. Remove the CMP sensor. Installation Procedure Locations Pedal Positioning Sensor: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Lower Left Side of the Instrument Panel Components (1 of 2) Page 8471 Pedal Positioning Sensor: Diagrams Component Connector End Views Brake Pedal Position (BPP) Sensor Page 2366 Page 4701 Front Side Door Window Switch Bezel Replacement Front Door Panel: Service and Repair Front Side Door Window Switch Bezel Replacement Front Side Door Window Switch Bezel Replacement 6T30/6T40/6T45 - Automatic Transmission Transmission Speed Sensor: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Output Speed Sensor Replacement Output Speed Sensor Replacement Input Speed Sensor Replacement Input Speed Sensor Replacement Removal Procedure 1. Remove the transmission control valve body cover. Page 1688 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 5550 Outside Rearview Mirror - Passenger (DD0) Outside Rearview Mirror - Passenger (D49 or DP2) Page 4430 Transmission Mode Indicator - A/T: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Automatic Transmission Control Indicator Replacement Page 3631 13 - Front Differential Transfer Driven Gear 14 - Front Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual Valve Disassembled Views Disassembled Views Case and Associated Parts Page 7243 Customer TPMS Information Page 1867 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement Removal Procedure 1. Remove the drive belt. Refer to Drive Belt Replacement (See: Drive Belt/Service and Repair). 2. Remove the right side engine mount. Refer to Engine Mount Replacement (See: Engine Mount/Service and Repair/Engine Mount Replacement). 3. Remove the drive belt tensioner bolts (2). 4. Remove the drive belt tensioner (1) with drive belt tensioner bolt (2) from top of vehicle. Installation Procedure Note: Install the accessory drive belt tensioner and bolt as an assembly. Page 6520 X308 Inline Harness Connector End Views X308 Body Harness to Left Seat Inflatable Restraint Impact Module Jumper Harness and Pretensioner Page 6075 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 8190 Page 6099 Auxiliary Power Outlet: Tools and Equipment Special Tools Page 4232 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Page 3677 Page 4882 11. Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme right and extreme left turn conditions. If the hose makes contact, remove the hose and correct the condition. 12. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding). 13. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 14. Lower the vehicle. Page 6536 X501 Inline Harness Connector End Views X501 Left Front Door Harness to Left Front Door Trim Pad Harness Page 5527 4T45-E - Automatic Transmission Shifter A/T: Service and Repair 4T45-E - Automatic Transmission Floor Shift Control Knob Replacement Removal Procedure 1. Release the boot (2) from the shift control knob (1) by pulling the boot retainer downward. 2. Remove the shift knob retaining screw (3). 3. Remove the shift knob (1) from the shift control. Installation Procedure 1. Install the shift knob (1) from the shift control. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Page 1861 Drive Belt: Service and Repair Drive Belt Replacement Special Tools EN-48932 - Hydraulic Belt Tensioner Compressor For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). Note: the tensioner stop is critical and must be removed prior to Compressing the drive belt tensioner spring. 2. If equipped, remove the tensioner stop fastener (1) and stop (2). 3. Install the EN-48932 compressor to the drive belt tensioner spring. 4. Compress the drive belt tensioner spring fully using the EN-48932 - compressor. Page 9635 Seat Heater: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 3118 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LAT or LE5 or LE9) Engine Coolant Temperature (ECT) Sensor (LY7) Caster Description Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Page 5849 "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN(s) 19118426 and 20968489 will not be eligible for RIM management. * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Service Procedure Replace Wire Harness Connector 2010 Chevrolet Malibu and 2010 Pontiac G6 Tools Required - J 38125-7 Crimp Tool - J 38125-6 Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Seat shown out-of-vehicle for illustration purposed Page 7019 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 1245 Heater Hose: Service and Repair Heater Outlet Hose Replacement - Heater Core to Connector Heater Outlet Hose Replacement - Heater Core to Connector Page 2659 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Page 8164 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Page 9873 Page 9660 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Bosch Connectors Bosch Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 2004 36. Install the timing chain oiling nozzle. Tighten the timing chain oiling nozzle bolt to 10 Nm (89 lb in). 37. Apply sealant compound to the thread of the timing chain guide bolt access hole plug. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the recommended sealant. 38. Install the timing chain guide bolt access hole plug. Tighten the access hole plug to 90 Nm (66 lb ft). 39. Install the engine front cover. Refer to Engine Front Cover Replacement (See: Timing Cover/Service and Repair). 40. Install the camshaft cover. Refer to Camshaft Cover Replacement (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 41. Install the number 1 cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). Page 9836 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Water Deflector Replacement Air Inlet Grille Panel Water Deflector Replacement Diagrams Ignition Control Module: Diagrams Component Connector End Views Ignition Control Module (ICM) (LZ4 or LZE) Page 7244 Page 6507 X110 Inline Harness Connector End Views X110 Forward Lamp to Right Headlamp Harness X130 Inline Harness Connector End Views X130 Engine Harness to Fuel Injector Harness (LAT or LE5 or LE9) Page 1914 7. LAT only: 1. Install the generator control module coolant pump to the oil pan. Ensure that the anti-rotation tab is inserted into the hole in the oil pan. 2. Install the generator control module coolant pump bolt (3) and tighten to 25 Nm (18 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the generator control module coolant pump (2). 8. Lower the vehicle. 9. Using the engine support fixture, lower the engine. 10. Install the engine mount. Refer to Engine Mount Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Engine Mount Replacement). 11. Remove the engine support fixture. 12. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement (See: Engine Oil Dip Stick - Dip Stick Tube/Service and Repair). 13. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 14. Fill the engine oil to the proper level. Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Page 6705 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 2367 Engine Control Module: Description and Operation Engine Control Module Description The engine control module (ECM) interacts with many emission related components and systems, and monitors the emission related components and systems for deterioration. OBD II diagnostics monitor the system performance and a diagnostic trouble code (DTC) sets if the system performance degrades. The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type. A DTC is ranked as a Type A or Type B if the DTC is emissions related. Type C is a non-emissions related DTC. The ECM is in the engine compartment. The ECM is the control center of the engine controls system. The ECM controls the following components: * The fuel injection system * The ignition system * The emission control systems * The on-board diagnostics * The A/C and fan systems * The throttle actuation control (TAC) system The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect the vehicle performance and the emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the MIL. When the ECM detects a malfunction, the ECM stores a DTC. The condition area is identified by the particular DTC that is set. This aids the technician in making repairs. ECM Function The engine control module (ECM) can supply 5 V or 12 V to the various sensors or switches. This is done through pull-up resistors to the regulated power supplies within the ECM. In some cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is too low. Therefore, a DMM with at least 10 Mohm input impedance is required in order to ensure accurate voltage readings. The ECM controls the output circuits by controlling the ground or the power feed circuit through the transistors or a device called an output driver module. EEPROM The electronically erasable programmable read only memory (EEPROM) is a permanent memory that is physically part of the engine control module (ECM). The EEPROM contains program and calibration information that the ECM needs in order to control the powertrain operation. Special equipment, as well as the correct program and calibration for the vehicle, are required in order to reprogram the ECM. Data Link Connector (DLC) The data link connector (DLC) is a 16-pin connector that provides the technician a means of accessing serial data for aid in the diagnosis. This connector allows the technician to use a scan tool in order to monitor the various serial data parameters, and display the DTC information. The DLC is located inside of the drivers compartment, underneath the dash. Malfunction Indicator Lamp (MIL) The malfunction indicator lamp (MIL) is inside of the instrument panel cluster (IPC). The MIL is controlled by the engine control module (ECM) and illuminates when the ECM detects a condition that affects the vehicle emissions. ECM Service Precautions The engine control module (ECM), by design, can withstand the normal current draws that are associated with the vehicle operations. However, care must be used in order to avoid overloading any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the ECM circuits unless the diagnostic procedure instructs you to do so. These circuits should only be tested with a DMM. Emissions Diagnosis For State I/M Programs This OBD II equipped vehicle is designed to diagnose any conditions that could lead to excessive levels of the following emissions: * Hydrocarbons (HC) * Carbon monoxide (CO) * Oxides of nitrogen (NOx) Page 3716 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Air Conditioning Compressor and Condenser Hose Replacement Hose/Line HVAC: Service and Repair Air Conditioning Compressor and Condenser Hose Replacement Air Conditioning Compressor and Condenser Hose Replacement Page 6304 Fuel Injector 6 (LY7) Fuel Injector 6 (LZ4 or LZE) Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 1763 Note: Ensure that the alignment mark made previously on the intake camshaft actuator is still aligned properly with the mark on the timing chain. 1. Install the timing chain onto the intake camshaft actuator. 2. Align the intake camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft rotating the exhaust camshaft clockwise, if required. 3. Install a NEW intake camshaft actuator bolt (1) until snug. 4. Remove the timing chain retention tool (1) from the intake side of the timing chain. Page 5011 Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front Wheel Speed Sensor (WSS) - Left Rear Page 8479 Audio Amplifier X2 (UQA) Page 7304 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. Consult your repair material supplier for the proper stitching tool. Safety Cage Some run flat tires may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection Page 5325 Page 4063 7. Remove the inner snap ring. 8. Using J 41227, remove the sleeve from the stub shaft (94). Service and Repair Air Injection Check Valve: Service and Repair Secondary Air Injection Check Valve Pipe Replacement Page 2404 Page 10103 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. Page 4290 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Page 6324 Heated Seat Control Module - Driver X2 (KA1) Page 6147 Page 5663 Body Control Module (BCM) X3 Page 5695 X318 Inline Harness Connector End Views X318 DVD Signal Cable 3B to DVD Signal Cable 2B (SPO Accessory) (UJ5) Page 4496 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Page 7285 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Page 6784 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 9432 Driver or Passenger Seat Back Cushion Finish Panel Replacement Driver or Passenger Seat Back Cushion Finish Panel Replacement Page 7242 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 5218 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 4140 Shift Solenoid: Connector Views Component Connector End Views 1-2 Shift Solenoid (SS) Valve (ME7 or MN5) 2-3 Shift Solenoid (SS) Valve (ME7 or MN5) Locations Solar Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 3267 Catalytic Converter: Service and Repair Catalytic Converter Replacement - Left Side Catalytic Converter Replacement - Left Side Special Tools J 39194-B Heated Oxygen Sensor Wrench Removal Procedure Caution: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. Caution: The use of excessive force may damage the threads in the exhaust manifold/pipe. Note: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S. Note: The HO2S may be difficult to remove when the engine temperature is less than 48°C (120°F) 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair). 2. Remove the connector position assurance (CPA) retainer (5). 3. Disconnect the engine wiring harness electrical connector (4) from the heated oxygen sensor (HO2S) electrical connector (3). 4. Remove the HO2S electrical connector rosebud clip from the oil level indicator tube tab. Page 5991 Page 3808 Shift Solenoid: Connector Views Component Connector End Views 1-2 Shift Solenoid (SS) Valve (ME7 or MN5) 2-3 Shift Solenoid (SS) Valve (ME7 or MN5) Page 6412 Speaker - Right Front (UQA) Speaker - Right Front (UQ3) Page 9517 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Page 2665 Page 4367 Important: The larger radius corners of the cage windows should be positioned up and the grooved surface of the inner race should be visible. 13. Position the housing (2) and the inner race so that they are level in the vise. 14. Rotate the appropriate components, and align the cage windows and the inner race ball bearing tracks with the outer race ball bearing (1) tracks. 15. Position a cage window and the inner race ball bearing track for the ball bearing installation. Important: When performing the following procedure, the opposing cage window and the inner ball bearing track will be accessible for the ball bearing installation. 16. Press down on the cage following one of the outer race ball bearing tracks. 17. Install the ball bearing through the cage window onto the inner race ball bearing track. Important: The following service procedure will have to be performed after each ball bearing has been installed. 18. After the first ball bearing has been installed, use a brass drift and a hammer and gently tap the cage in order to drive the cage and the inner race down completely in the outer race. Important: After the ball bearing has been installed, there should be NO GAP between the ball bearing and the inner race. 19. Position the cage and the inner race so that they are level. 20. Using a plastic hammer, lightly tap the ball bearing into place. 21. Install the ball bearings in sequence. 22. Repeat steps 18-20 until all the ball bearings are installed. 23. If any of the internal parts are found to be defective, replace the outer joint. Refer to Wheel Drive Shaft Outer Joint and Boot Replacement (See: Service and Repair/Wheel Drive Shaft Outer Joint and Boot Replacement). Page 4695 Traction Control Switch: Service and Repair Electronic Traction Control Switch Replacement Page 5680 X180 Inline Harness Connector End Views X180 Left Repeater Lamp Harness to Forward Lamp Harness Locations Cabin Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component Views Behind Right Side and Center of the Instrument Panel Components 1 - Mode Actuator 2 - Air Temperature Sensor - Upper (C68) 3 - Air Temperature Actuator 4 Recirculation Actuator 5 - Air Temperature Sensor - Lower (C68) Page 6797 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Page 6026 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Connector Position Assurance Locks Connector Position Assurance Locks Page 7730 Page 7210 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 5464 Evaporative Emission (EVAP) Canister Purge Solenoid Valve (LY7) Evaporative Emission (EVAP) Canister Purge Solenoid Valve (LZ4 or LZE) Page 6855 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Page 7866 Page 6417 Starter Generator X3 (KY1) Starter Generator X4 (KY1) Starter Generator Control Module (SGCM) X1 (LAT) Page 10017 Page 2141 Heater Hose: Service and Repair Heater Outlet Hose Replacement - Connector to Engine Heater Outlet Hose Replacement - Connector to Engine Page 9632 Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Locations Washer Fluid Level Switch: Locations Front of Vehicle/Engine Compartment Component Views Front and Right Rear of the Engine Compartment Components 1 - A/C Refrigerant Pressure Sensor 2 - Engine Cooling Fan - Right 3 - Engine Cooling Fan - Left 4 - Windshield Washer Fluid Pump 5 - Windshield Washer Fluid Level Switch 6 - Horn Assembly Page 6223 Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake (LY7) Page 10438 Page 6385 Radio X1 Page 2331 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 6228 Camshaft Position (CMP) Sensor - Bank 2 Exhaust (LY7) Page 9458 Seat Cushion: Service and Repair Seat Cushion Outer Trim Panel Replacement Seat Cushion Outer Trim Panel Replacement Page 839 1. Lubricate the NEW MAP sensor seal with clean engine oil. 2. Install the MAP sensor (1) into the intake manifold. 3. Connect the fuel injector wiring harness electrical connector (2) to the number 3 fuel injector. 4. Install the fuel injector wiring harness clips (1) to the fuel rail tabs. Page 7108 Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor (NVH) Page 4381 6. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race. 7. Hold the inner race 90 degrees to centerline of cage with the lands of the inner race (1) aligned with the windows of the cage (2) and insert the inner race into the cage. 8. Hold the cage and the inner race 90 degrees to centerline of the outer race (1) and align the cage windows (3) with the lands of the outer race. Note: Be sure that the retaining ring side of the inner race faces the halfshaft bar. 9. Place the cage and the inner race into the outer race. 10. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball. 11. Repeat this process until all 6 balls are in place. 12. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease. Page 1290 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement Special Tools J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the coolant. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 2. Reposition the radiator outlet hose clamp at the radiator using the J 38185. 3. Remove the radiator outlet hose from the radiator. 4. Reposition the radiator outlet hose clamp at the engine using the J 38185. 5. Remove the radiator outlet hose from the engine. 6. Remove the radiator outlet hose clamps from the radiator outlet hose. Installation Procedure 1. Install the radiator outlet hose clamps to the radiator outlet hose. Page 9050 5. Tilt the load floor rear compartment cover (2) towards the rear of the vehicle slightly, disengaging the tabs (1) and remove the load floor rear compartment cover. Installation Procedure 1. Tilt the load floor rear compartment cover (2) towards the rear of the vehicle slightly in order to insert the tabs (2) into the battery tray rear support. Page 5983 Page 8189 Page 1398 Page 5412 Digital Video Disc (DVD) Control Module X1 (SPO Accessory) (UJ5) Page 3311 15. Remove the caps from the fuel rail pipe and the EVAP purge solenoid. 16. Connect the EVAP line quick connect fitting (2) to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 17. Connect the fuel feed line quick connect fitting (3) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 18. Install the fuel feed line retainer (1) to the fuel line bracket. 19. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 21. Tighten the fuel fill cap. 22. Inspect for leaks. 1. Turn ON the ignition, with the engine OFF for 10 seconds. 2. Turn OFF the ignition for 10 seconds. 3. Turn ON the ignition, with the engine OFF. 4. Inspect for fuel leaks. Page 4420 1. Position the flywheel to the crankshaft. 2. Install the NEW flywheel bolts until snug. 3. Have an assistant install the J 38122-A, and a breaker bar to the crankshaft balancer in order to prevent the flywheel from rotating when tightening the flywheel bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the flywheel bolts. Tighten the bolts to 53 Nm (39 lb ft) plus an additional 25 degrees using the J 45059. 5. Remove the J 38122-A and breaker bar. 6. Install the transaxle. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement ). Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Charge .............................................................................................................................. ............................................................ 0.5 kg (1.1 lb) Page 9331 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Actuator Initialization/Teach Process Perform the Initialization/Teach Procedure any time a new sunroof motor actuator is installed in the vehicle. 1. Ensure that the electrical harness on the headliner is connected to the sunroof. 2. Press the sunroof switch to the open position until the window stalls at the rear hard stop in the fully open position, then moves slightly toward the soft stop position. Release the switch 3. Within 6 seconds, press and hold the open switch. After an additional 3 seconds, the sunroof window will move toward the close position. 4. Hold the switch until the sunroof window stops at the closed position. Release the switch. 5. Verify the operation of the sunroof. Important: The Initialization/Teach Procedure is not complete if any of the following actions take place before the initialization cycle is done: * The sunroof switch is not held in the open position. * The ignition and/or battery power has been removed. * The glass panel has not reached the closed position. The Initialization/Teach Process must be restarted if the procedure is not carried out completely. Tire Pressure Monitor - TPM System Message/Service Tips Tires: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Switch Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the oil pressure switch. 3. Remove the engine oil pressure switch. Installation Procedure Page 6479 Automatic Transmission Manual Shift Switch - Right (KB7) Page 4087 Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 8. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. Page 5141 Page 6456 Windshield Wiper Motor Windshield Wiper/Washer Switch Page 10023 Page 4875 10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405. 11. Install the tube nuts on the brake pipe, noting their orientation. 12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. 13. Loosen the die clamping screw of the J 45405. 14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram. Page 6305 Fuel Pump and Sender Assembly Fuel Tank Pressure (FTP) Sensor Steering Linkage Inner Tie Rod Inspection Tie Rod: Testing and Inspection Steering Linkage Inner Tie Rod Inspection Steering Linkage Inner Tie Rod Inspection Special Tools J-8001 - Dial Indicator Set For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: This inspection procedure does not supersede local government required inspections that have more stringent requirements. 1. Turn the ignition key to the ON position with the engine OFF. 2. With the aid of an assistant, turn the steering wheel to the full stop position and hold the steering wheel in that position until the test is complete. The tie rod being tested should be inside the steering gear housing seated against the steering stop. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 4. If there is not a good location for the J-8001 - Dial Indicator pointer at the steering gear housing, install a large worm gear hose clamp to the steering gear housing over the larger steering gear boot clamp and align the clamp so that the screw can be a location for the J-8001 - Dial Indicator pointer. 5. Install the J-8001 - Dial Indicator between the inner tie rod (2) and the steering gear housing or the worm gear clamp in such a way as to measure the lash between the inner tie rod and the steering gear housing. Page 9175 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 5410 Data Link Connector (DLC) Page 1365 connector housing. Refer to Repairing Connector Terminals in SI. 15. Insert the wire into the new conduit and tape the conduit end at the connector. Tape the conduit closed every 255 mm (10 in) with electrical tape. 16. Connect the fan end electrical connector into the cooling fan. 17. Fasten the new wire and conduit with tie wraps (GM P/N 12337820), as shown below. At the cooling fan end of the wire and conduit, leave adequate slack to allow for engine movement (white tie wraps are used for display purposes, use black tie wraps to match the original appearance). With RPO LY7 - Fasten the new wire and conduit to the existing harness with wire tie wraps as shown. With RPOs LZ9, LZ4 or LZE - Fasten the new wire and conduit to metal the transmission cooler lines as shown. (The lower cover has been removed to show the location of the wire tie wraps.) 18. Trim the wire and conduit to length at the underhood fuse block area. 19. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 20. Strip the wire insulation as required and install the terminal, GM P/N 15324340, on the wire. Refer to Repairing Connector Terminals in SI. 21. Reinstall the terminal into A2 on the junction block. Reinstall the TPA and the harness back cover. 22. Reconnect the harness to the under hood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 23. Reinstall the underhood fuse block into it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. Install the 40-amp fuse, GM P/N 15319478. 24. Reinstall the battery. Refer to Battery Replacement in SI. 25. Reinstall the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 26. Reinstall the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 27. Confirm the high speed cooling fan operation using the Tech 2(R). Parts Information Page 3728 Transmission Speed Sensor: Connector Views Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Output Shaft Speed (OSS) Sensor (MH2 or MH8) Page 5530 Inflatable Restraint Side Impact Sensor (SIS) - Right Page 4503 25 - A/Trans Fluid Pump Seal Assembly 26 - Torque Converter with Fluid Pump Housing Assembly 27 - Torque Converter and Differential Housing Bolt 28 - A/Trans Fluid Fill Tube Plug Assembly 29 - Torque Converter Assembly Component Location Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear Page 2425 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (7) to the intake CMP sensor (6). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Steering Wheel Replacement Steering Wheel: Service and Repair Steering Wheel Replacement Steering Wheel Replacement Page 5857 Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information 1. Submit a transaction using the table below. * The amount identified in the Net Item column should represent the actual cost of the woven polyester electrical tape, required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a customer satisfaction program that affects your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle. Page 9657 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 6249 Digital Video Disc (DVD) Display - Passenger Seat Headrest X1 (SPO Accessory) (UJ5) Tire Pressure Monitor - TPM System Message/Service Tips Tires: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 2492 Heated Oxygen Sensor (HO2S) 1 (LAT or LE5 or LE9 with MN5) Heated Oxygen Sensor (HO2S) 1 (LE5 or LE9 with MH8) Page 1044 25 - Torque Converter and Support and A/Trans Fluid Pump Housing Assembly 26 - Torque Converter and Differential Housing Bolt 27 - Torque Converter Assembly 28 - Dust Cover Push Pin - Model Dependent 29 - Dust Cover Bolt - Model Dependent 30 - Dust Cover - Model Dependent 31 - Front Differential Carrier Assembly 32 - Input Shaft Thrust Bearing Assembly 33 - A/Trans Case Cover Gasket 34 - A/Trans Case Cover Assembly 35 - A/Trans Case Cover Assembly Bolt A/Trans Case Cover, 2-6 and Low Reverse Pistons 400 - A/Trans Input Speed Sensor Assembly 401 - A/Trans Input Speed Sensor Bolt 402 - ISS O-Ring Seal 403 - A/Trans Case Cover Assembly 404 - 3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring 405 - 2-6 Clutch Piston 406 - 2-6 Clutch Spring Assembly 407 - 2-6 Clutch Spring Retainer Ring 408 - Low and Reverse Clutch Piston Assembly 409 - Low and Reverse Clutch Spring 410 Low and Reverse Clutch Spring Retainer Ring Testing and Inspection Radiator Cap: Testing and Inspection Pressure Cap Testing Special Tools * J 24460-01 Cooling System Pressure Tester * J 42401 Radiator Cap/Surge Tank Test Adapter Warning To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. 1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. Note: Lubricate J 42401 and pressure cap O-rings with coolant and press cap to seat O-ring on J 42401 before turning to engage threads. 3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. 4. Test the pressure cap for the following conditions: * Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. * Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss. 5. Replace the pressure cap under the following conditions: * The pressure cap does not release pressure which exceeds the rated pressure of the cap. * The pressure cap does not hold the rated pressure. Page 2769 Page 6241 Digital Video Disc (DVD) Control Module X1 (SPO Accessory) (UJ5) Page 8246 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Delphi Connectors Delphi Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 4549 25 - Torque Converter and Support and A/Trans Fluid Pump Housing Assembly 26 - Torque Converter and Differential Housing Bolt 27 - Torque Converter Assembly 28 - Dust Cover Push Pin - Model Dependent 29 - Dust Cover Bolt - Model Dependent 30 - Dust Cover - Model Dependent 31 - Front Differential Carrier Assembly 32 - Input Shaft Thrust Bearing Assembly 33 - A/Trans Case Cover Gasket 34 - A/Trans Case Cover Assembly 35 - A/Trans Case Cover Assembly Bolt Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Page 9293 Seat Heater Control Module: Diagrams Component Connector End Views Heated Seat Control Module - Driver X1 (KA1) Heated Seat Control Module - Driver X2 (KA1) Page 8929 Grille: Service and Repair Radiator Grille Opening Cover Replacement Radiator Grille Opening Cover Replacement Page 4783 Brake Rotor/Disc: Specifications Front Brakes Rotor Discard Thickness ..................................................................................................................... .................................................... 22.8 mm (0.898 in) Rotor Minimum Allowable Thickness After Refinish ............................................................................................................................. 23.0 mm (0.906 in) Rotor Maximum Allowable Assembled Lateral Runout .......................................................................................................................... 0.05 mm (0.002 in) Rotor Maximum Allowable Thickness Variation .................................................................................................................................. 0.025 mm (0.001 in) Rear Brakes Rotor Discard Thickness ..................................................................................................................... .................................................... 11.8 mm (0.465 in) Rotor Maximum Allowable Assembled Lateral Runout .......................................................................................................................... 0.05 mm (0.002 in) Rotor Minimum Allowable Thickness After Refinish ............................................................................................................................. 12.0 mm (0.472 in) Rotor Maximum Allowable Thickness Variation .................................................................................................................................. 0.025 mm (0.001 in) Page 4225 Locations Heated Glass Element Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Exploded Views Transmission Speed Sensor: Exploded Views Disassembled Views Disassembled Views Case and Associated Parts (1 of 3) 1 - Side Cover (Structural) 2 - Axle Oil Seal 3 - Side Cover Bolt 4 - Side Cover Stud 5 - Side Cover Gasket 6 - Side Cover Oil Level Control Gasket 7 - Thrust Washer (Side Cover to Driven Sprocket) 8 - Oil Pump Bolt 9 - Oil Pump Bolt 10 - Transaxle Oil Pump Assembly 11 - Transaxle Wiring Assembly 12 - TFP Manual Valve Position Switch Assembly Bolt 13 - TFP Manual Valve Position Switch Assembly 14 - Wiring Harness Pass-Through Connector O-Ring Seal 15 - Wiring Harness Bracket Bolt/Input Speed Sensor Bolt 51 - Transaxle Case 52 - Vent Cap 55 - Torque Converter Assembly 61 - Output Speed Sensor Stud 62 - Output Shaft Speed Sensor 63 - O-Ring Seal (Output Speed Sensor) 64 - Band Anchor Pin (Lo/Reverse) 65 - Oil Level Control Plug 81 - Tube Assembly Bolt/Bottom Pan Bolt 84 - Transaxle Oil Filter Seal Page 4124 2. Attach the ball-sockets to the control assembly body and the shift-lock control lever. 3. Connect the electrical connector to the Shift Lock Control Solenoid. 4. Install the automatic transaxle control assembly. Page 6603 Fuse Block - Underhood Top View (LY7) Page 8289 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the MYLAR tape. If the MYLAR tape is damaged, use 3M product AL-36FR to replace the damaged MYLAR tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Duct Air Temperature Sensor Replacement - Upper Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Duct Air Temperature Sensor Replacement - Upper Page 279 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Page 5534 Inflatable Restraint Steering Wheel Module Coil X3 Page 4382 13. Push the CV joint (2) onto the halfshaft bar (1) until the retaining ring is seated in the groove on the halfshaft bar. Note: The outboard seal (1) must not be dimpled, stretched or out of shape in any way. If the outboard seal (1) is not shaped correctly, equalize the pressure in the outboard seal (1) and shape the seal properly by hand. 14. Slide large diameter of the outboard seal (1) with the large seal retaining clamp (2) in place over the outside of the CV joint outer race (3) and locate the seal lip in the groove on the CV joint outer race. Page 9618 Page 2417 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor - Bank 1 Exhaust (LY7) Camshaft Position (CMP) Sensor - Bank 1 Intake (LY7) Page 733 For vehicles repaired under warranty use the table above. Disclaimer Page 4798 4. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 conical brake rotor washers (1), and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 6. Install the remaining CH-45101-100 - conical brake rotor washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the CH-39544-KIT - complete torque socket set - 10 pcs, or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14. 9. If the brake rotor meets the following criteria, proceed to step 10. * The rotor is within specifications and is being REUSED. * The rotor has NOT been refinished. * The rotor does NOT exhibit thickness variation exceeding the maximum allowable level. Page 593 Lateral Accelerometer: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor Page 534 Page 4855 Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Page 9521 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Page 3105 Camshaft Position (CMP) Sensor - Bank 2 Intake (LY7) Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure Important: If replacing the steering wheel position sensor, the new sensor MUST come with a locating pin installed. If a locating pin is not installed, return and reorder a new steering wheel position sensor. Do not apply force to the steering wheel position sensor in a sideways direction. When reusing the steering wheel position sensor you must install a locating pin before removing it from the steering column. If the steering wheel position sensor loses its correct position it must be discarded. The locating pin diameter must be in the range of 1.0-2.0 mm. 1. Set the front wheels in the straight-ahead position and install anti-rotation pin J 42640 in the steering column lower access hole. 2. Disconnect the intermediate steering shaft from the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 3. Disconnect any electrical connectors as needed. 4. Remove the steering wheel position sensor. Assembly Procedure Page 2704 Data Link Connector: Diagrams Component Connector End Views Data Link Connector (DLC) Page 10392 License Plate Lamp: Service and Repair Rear License Plate Lamp Replacement Page 1443 Fuse Block - Underhood Top View (LAT) Electrical - Various Electrical Concerns/False Messages Door Switch: Customer Interest Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Page 3054 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (LAT) Page 5144 Specifications Compressor Clutch: Specifications Air Gap ................................................................................................................................................ ................................... 0.3-0.6 mm (0.012-0.024 in) Service and Repair Maintenance Required Lamp/Indicator: Service and Repair SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator. This indicator is not a maintenance indicator and does not mean a maintenance service is required. For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information refer to Malfunction Indicator Lamp. For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. Page 6600 Page 8225 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Page 6349 Ignition Control Module (ICM) (LZ4 or LZE) Page 4626 Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 8. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. Page 5512 Ignition Coil 2 (LAT or LE5 or LE9) Page 8892 Body Emblem: Service and Repair Rear Compartment Lid Emblem/Nameplate Replacement Rear Compartment Lid Emblem/Nameplate Replacement Page 10593 Page 6256 Door Lock Switch - Passenger Page 664 3. Install the refrigerant pressure sensor wire harness connector. 4. Leak test the fittings using the J 39400-A. Page 994 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Page 10080 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 7183 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the wheel bearing/hub mounting bolts (1) and tighten to 115 Nm (85 lb ft). Page 9132 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Locations Crankshaft Position Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 7418 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Separator Removal Procedure 1. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 4. Using the J 43631, release the wheel stud from the bearing hub and discard the stud. Installation Procedure Page 4828 14. Remove the park brake cable from the caliper. 15. Remove the brake caliper from the brake caliper bracket. Installation Procedure 1. Inspect the caliper slide boots for cuts, tears, or deterioration. If damaged, replace the slides and boots. Refer to Rear Brake Caliper Hardware Replacement (See: Rear Brake Caliper Hardware Replacement). 2. Install the brake caliper to the brake caliper bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 2 brake caliper pin bolts and tighten to 35 Nm (26 lb ft). Page 5678 X110 Inline Harness Connector End Views X110 Forward Lamp to Right Headlamp Harness X130 Inline Harness Connector End Views X130 Engine Harness to Fuel Injector Harness (LAT or LE5 or LE9) Page 9500 Page 4589 Control Module: Diagrams Component Connector End Views Automatic Transmission Auxiliary Fluid Pump Control Module (HP7 with ME7) Transmission Control Module (TCM) (ME7) Page 9617 Page 9137 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Page 1418 Page 3070 Engine Control Module (ECM) X3 (LY7) Page 4333 14. Start the engine, warm up the transaxle, and check for leaks. 15. Inspect for proper fluid level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Symptom Related Diagnostic Procedures/4T45-E - Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 16. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and Operation/4T45-E - Automatic Transmission/Transmission Adaptive Functions). Page 2420 Camshaft Position (CMP) Sensor - Exhaust (LAT or LE5 or LE9) Page 4964 Page 4825 Installation Procedure 1. Install the brake caliper to the brake caliper bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the brake caliper guide pin bolts (2) and tighten to 35 Nm (26 lb ft). 3. Remove the caps or plugs from the brake caliper opening and the brake hose. Note: Do not reuse the copper brake hose gaskets. 4. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3). 5. Install the brake hose and the brake hose-to-brake caliper bolt to the brake caliper and tighten the bolt to 50 Nm (37 lb ft). 6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding). Body Control Module Fuse: Application and ID Body Control Module Electrical Center Identification Views Body Control Module (BCM) Label Page 2142 Heater Hose: Service and Repair Heater Outlet Hose Replacement - Heater Core to Connector Heater Outlet Hose Replacement - Heater Core to Connector Page 10104 GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The Page 5808 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. Page 5625 Window Switch - Right Rear Page 7233 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Page 4111 Transmission Speed Sensor: Service and Repair 6T70/6T75 - Automatic Transmission Output Speed Sensor Replacement Output Speed Sensor Replacement Input Speed Sensor Replacement Input Speed Sensor Replacement Page 7294 Tires: Description and Operation Tire Inflation Description Tire Inflation Description This vehicle has been engineered to operate up to the stated load capacity with wheel and tire assemblies of the type, size, construction, and configuration as originally installed. Maintenance of the tire inflation pressures is critical to the continued satisfactory performance, handling, and operating economy of the vehicle. Operation with incorrectly or improperly inflated tires can adversely affect vehicle performance and may contribute to the following: * Reduced fuel economy * Tire overloading * Shortened tire life * Excessive tire wear * Uneven tire wear * Vehicle handling concerns Inspect the tire pressures when the vehicle has not been driven for at least 3 hours or not more than 1.6 km (1 mi) and when the tires are cool to the touch. Tire inflation pressures should be inspected monthly and before an extended trip and adjusted to meet the specifications listed for the particular vehicle. Replace any missing or damaged tire valve stem extensions and/or caps to prevent the intrusion of water and contaminates. One pound per square inch (psi) equals 6.9 kilopascals (kPa). The following table illustrates the conversion of kilopascals to pounds per square inch: For the correct inflation pressures refer to the vehicle's Tire Placard. Tires inflated to a higher than recommended pressure can contribute to the following conditions: * A hard ride * Tire bruising * Rapid tread wear at the center of the tire Tires inflated to a lower than recommended pressure can contribute to the following conditions: * Tire squeal on turns * Hard steering * Rapid and/or uneven wear on the outer edges of the tread * Tire rim bruises and tire rim rupture * Tire cord breakage * High tire temperatures * Sluggish vehicle handling * Higher fuel consumption Unequal pressure on the same axle can cause the following conditions: Page 3303 12. Raise the muffler assembly into position. 13. With the aid of an assistant, install the muffler insulators (1) to the underbody hangers. 14. Remove the jackstand from under the muffler assembly. 15. Lower the vehicle. Page 9044 Rear Window Shelf Trim Panel Replacement Rear Window Shelf Trim Panel Replacement Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ........................................ 345-414 kPa (50-60 psi). Verify the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 5492 Heated Oxygen Sensor (HO2S) 1 (LAT or LE5 or LE9 with MN5) Heated Oxygen Sensor (HO2S) 1 (LE5 or LE9 with MH8) Page 57 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 2821 Page 6164 Page 6402 Seat Rear Vertical Motor - Driver (LTZ) Service and Repair Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Removal Procedure Note: The driver door window regulator and motor MUST be replaced as an assembly. The right door is serviceable as door window regulator or motor. 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair/Front Side Door Trim Panel Replacement). 2. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service and Repair/Front Side Door Water Deflector Replacement). 3. Raise the window far enough in order to gain access to the bolts (1, 2) that attach the window to the regulator. 4. Remove the bolts (1, 2) that attach the window to the regulator. 5. Raise the window to the full up position and tape in place. 6. Disconnect the electrical connector (2) from the power window motor. 7. Remove the front door window regulator. Refer to Front Side Door Window Regulator Replacement (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Front Side Door Window Regulator Replacement). 8. Remove the window regulator and motor through the access opening in the inner panel. 9. Remove the power window motor bolts from the window regulator. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Page 3542 Ignition Coil: Service and Repair Ignition Coil Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connectors (1) from the ignition coil(s) (2). 3. Remove the ignition coil bolt(s). 4. Remove the ignition coil(s). Installation Procedure Page 3917 7. Inspect the fluid color. The fluid should be red or dark brown. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal particles or other debris. A small amount of "friction" material is a "normal" condition. If large pieces and/or metal particles are noted in the fluid, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs of transmission internal damage noted, replace the fluid, repair the oil cooler, and flush the cooler lines. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission (See: Testing and Inspection/Symptom Related Diagnostic Procedures/6T30/6T40/6T45 - Automatic Transmission/Engine Coolant/Water in Transmission). 8. Inspect for external leaks. Refer to Fluid Leak Diagnosis (See: Testing and Inspection/Component Tests and General Diagnostics/6T30/6T40/6T45 - Automatic Transmission/Fluid Leak Diagnosis). 9. If the fluid was changed, reset the transmission oil life monitor if applicable. Dipstick Level Checking Procedure (If equipped) 1. Park the vehicle on a level surface, apply the parking brake and place the shift lever in PARK (P). Start the engine. 2. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in each range. Then move the shift lever back to PARK (P). 3. Allow the engine to idle 500-800 rpm for at least 3 minutes to allow any fluid foaming to dissipate and the fluid level to stabilize. Release the brake pedal. 4. Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver Information Center or a scan tool. Caution: The transmission fluid level must be checked when the transmission fluid temperature (TFT) is at 85-95°C (185-203°F). If the TFT is not at this temperature, operate the vehicle or allow the fluid to cool as required. Setting the fluid level with a TFT outside this temperature will result in either an under or over-filled transmission. TFT 95°C under-filled, TFT 85°C over-filled. An under-filled transmission will cause premature component wear or damage. An over-filled transmission will cause fluid to discharge out the vent tube, fluid foaming, or pump cavitation. Note: * If the TFT reading is not at the required temperature, allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached. If the fluid temperature is below the specified range, perform the following procedure to raise the fluid temperature to the specification. * Check the transmission fluid level when the TFT is at between 85-95°C (185-203°F). The fluid level rises as fluid temperature increases, so it is important to ensure the transmission fluid temperature is at the specified temperature. Drive the vehicle in second gear until the fluid temperature is at the specified temperature. 5. The vehicle must be level, with the engine running and the shift lever in the PARK range. 6. Remove the dipstick and wipe it with a clean rag or paper towel. 7. Inspect the fluid color. The fluid should be red or dark brown. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal particles or other debris. A small amount of "friction" material is a "normal" condition. If large pieces and/or metal particles are noted in the fluid, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs of transmission internal damage noted, replace the fluid, repair the oil cooler, and flush the cooler lines. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission (See: Testing and Inspection/Symptom Related Diagnostic Procedures/6T30/6T40/6T45 - Automatic Transmission/Engine Coolant/Water in Transmission). 8. Install the dipstick. Wait three seconds and then remove it again. Note: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent cap to ensure it is clean and unclogged. Note: It is not necessary to get the fluid level all the way up to the MAX mark. Anywhere within the crosshatch band is acceptable. 9. Check both sides of the dipstick and read the lower level. 10. Install and remove the dipstick again to verify the reading. Note: Do not add more than one half pint (0.25L) at a time without rechecking the level. Once the oil is on the dipstick bullet, it will not take much more fluid to raise the fluid level into the crosshatch band. Do not overfill. Also, if the fluid level is low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis (See: Testing and Inspection/Component Tests and General Diagnostics/6T30/6T40/6T45 - Automatic Transmission/Fluid Leak Diagnosis). 11. If the fluid level is not within the crosshatch band, and the transmission temperature is at 90°C (194°F), add or drain fluid as necessary to bring the level into the crosshatch band. If the fluid level is low, add only enough fluid to bring the level into the crosshatch band. 12. If the fluid level is in the acceptable range, install the dipstick. Page 6465 Accessory Power Outlet - Center Console Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 9062 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Page 2357 Engine Control Module (ECM) X2 (LE5 or LE9) Page 1815 2. Connect the clip (1) to the transmission range selector lever cable bracket (2). 3. Connect the engine coolant heater cord (1). 4. Reposition the surge tank and install the fasteners. Refer to Radiator Surge Tank Replacement (See: Cooling System/Coolant Reservoir/Service and Repair/Radiator Surge Tank Replacement). Page 1987 Timing Chain Tensioner: Service and Repair Camshaft Timing Chain, Sprocket, and Tensioner Replacement Camshaft Timing Chain, Sprocket, and Tensioner Replacement Special Tools * EN-45027 - Tensioner Tool * EN-45059 - Angle Meter For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the number 1 cylinder spark plug. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 2. Rotate the crankshaft in the engine rotational direction clockwise, until the number 1 piston is at top dead center (TDC) on the exhaust stroke. 3. Remove the camshaft cover. Refer to Camshaft Cover Replacement (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 4. Remove the engine front cover. Refer to Engine Front Cover Replacement (See: Timing Cover/Service and Repair). 5. Remove the upper timing chain guide bolts and guide. Page 2757 Locations Power Mirror Switch: Locations Door Component Views Driver Door Components 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Page 4876 15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies. 16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1). 17. Remove the unused die (1). 18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage. 19. Firmly hand tighten the clamping screw (2) against the dies. 20. Select the appropriate forming mandrel and place into the forming ram. 21. Rotate the hydraulic fluid control valve clockwise to the closed position. 22. Rotate the body of the J 45405 until it bottoms against the die cage. Page 8281 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 2257 1. Remove the catalytic converter. Refer to Catalytic Converter Replacement - Right Side (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Right Side). 2. Remove the exhaust manifold lower heat shield bolts (1, 2). 3. Remove the exhaust manifold lower heat shield. Installation Procedure 1. Position the exhaust manifold lower heat shield to the engine. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust manifold lower heat shield bolts (1, 2). * Tighten the bolt (1) to 10 Nm (89 lb in). * Tighten the bolt (2) to 50 Nm (37 lb ft). 3. Install the catalytic converter. Refer to Catalytic Converter Replacement - Right Side (See: Catalytic Converter/Service and Repair/Catalytic Page 3939 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: The correct thread engagement is critical. Cross-threaded fittings can achieve proper tightness and still leak. 2. Install the oil cooler fitting to the radiator and tighten to 38 Nm (28 lb ft). 3. Install the transaxle oil cooler hoses to the oil cooler fittings on the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 5. Adjust the transmission fluid level. 6. Inspect for fluid leaks. Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Removal Procedure Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. Page 9481 Page 5204 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Bosch Connectors Bosch Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 7768 Solar Sensor: Diagrams Component Connector End Views Sunload Sensor (C68) Diagrams Center Mounted Brake Lamp: Diagrams Component Connector End Views Center High Mounted Stop Lamp (CHMSL) Page 5199 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Page 5190 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Page 5116 Starter Motor: Diagrams Component Connector End Views Starter Motor X1 Starter Motor X2 (Starter to Battery) (LAT or LE5) Starter Motor X2 (Starter to Battery) (LY7) Starter Motor X2 (Starter to Generator) (LAT or LE5 or LE9) Page 8856 Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3 or HP7) Locations Hood Sensor/Switch (For Alarm): Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (2 of 2) 1 - Hood Ajar Switch (AP3) Page 4560 Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover Replacement). 13. If a NEW TCM has been installed into the vehicle, the NEW module needs to be reprogrammed. Refer to Service Programming System (SPS) ( See: Testing and Inspection/Programming and Relearning/Service Programming System (SPS)). Note: The Service Fast Learn Adapts procedure must be performed when one of the following repairs have been made to the vehicle. Failure to perform the procedure after one of the following repairs may result in poor transmission performance, as well as transmission DTCs being set: * Transmission internal service/overhaul * Valve body repair or replacement * Control solenoid valve assembly replacement * TCM software/calibration update * Any service in response to a shift quality concern 14. Perform the Service Fast Learn Adapts. Refer to Service Fast Learn Adapts (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning/6T70/6T75 - Automatic Transmission). Page 2667 Body Control Module: Service and Repair Body Control Module Replacement Page 5482 Generator Battery 3 (+) (HP7) Generator Battery Assembly X1 (HP7) Generator Battery Assembly X2 (HP7) Generator Battery Assembly X3 (HP7) Generator Battery Disconnect Control Module X1 (LAT) Page 2264 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust pipe heat shield nuts and tighten to 10 Nm (89 lb in). 3. Install the exhaust heat shield. Refer to Exhaust Heat Shield Replacement (See: Exhaust Heat Shield Replacement). Page 3891 Control Module: Diagrams Component Connector End Views Automatic Transmission Auxiliary Fluid Pump Control Module (HP7 with ME7) Transmission Control Module (TCM) (ME7) Page 9795 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Page 9762 Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3 or HP7) Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Page 3056 Page 1971 Engine Oil Pressure (EOP) Switch (LY7) Page 7968 Your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle not only meets, but exceeds government standards for side impact protection. GM recently introduced into production, changes that add to that protection. At no charge, your dealer will make similar changes to your vehicle, which was built before the production change. What We Will Do: To enhance the side impact protection, your GM dealer will update the wiring harness for both front seat side impact airbags. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 10085 Page 4763 Installation Procedure 1. Install the brake pad retainers (2) to the brake caliper mounting bracket (3). 2. Install the brake pads (1) to the brake caliper mounting bracket (3). 3. Pivot the brake caliper downward, over the brake pads and into the caliper bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the brake caliper guide pin bolt to the brake caliper guide pin and tighten the bolt to 35 Nm (26 lb ft). 5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 6. Lower the vehicle. 7. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 8. Slowly release the brake pedal. 9. Wait 15 seconds, then repeat steps 11 and 12 until a firm brake pedal apply is obtained; this will properly seat the brake caliper pistons and brake pads. Page 5662 Page 3603 Caution: Do not coat spark plug threads with anti-seize compound. If anti-seize compound is used and spark plugs are over-torqued, damage to the cylinder head threads may result. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the spark plugs and tighten the plugs to 20 Nm (15 lb ft. The spark plug gap is 1.0 mm (0.040 in). 2. Install the ignition coil(s). Refer to Ignition Coil Replacement (See: Ignition Coil/Service and Repair). Page 9478 Page 2884 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Page 6252 Door Latch - Driver Door Latch - Left Rear Page 9989 ‹› If greater than the specified value, test the ground circuit for an open/high resistance. 3. Ignition ON, test for B+ between the B+ circuit terminal 4 and ground. ‹› If less than the specified value, test the circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the BCM. 4. Test for B+ between the B+ circuit terminal 4 and the signal circuit terminal 5. ‹› If less than the specified value, test the circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the BCM. 5. Ignition OFF, disconnect the X2 harness connector at the BCM. 6. Test for infinite resistance between the signal circuit terminal 5 and ground. ‹› If less than the specified value, test the signal circuit for a short to ground. 7. If all circuits test normal, test or replace the steering wheel control switch - left. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Steering Wheel Control Switch Assembly Replacement (See: Accessories and Optional Equipment/Sensors and Switches - Accessories and Optional Equipment/Steering Mounted Controls Assembly/Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning) for BCM replacement, setup, and programming Page 2010 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the engine front cover bolts and tighten to 25 Nm (18 lb ft). 4. Lower the vehicle. 5. Install the engine front cover to water pump bolt and tighten to 25 Nm (18 lb ft). Page 8353 Important These devices (and additional MP3 players) may be capable of connecting to the other USB options by internally setting the MP3 device to MSC (Mass Storage Class) mode. In this mode, the USB port will see the device as a flash drive. Please have the customer refer to their MP3 device manual on how to set the device to MSC. If the device is not able to be set to MSC, the customer must use the AUX jack. Note MTP mode must be used in order to transfer ANY Digital Rights Management (DRM) protected content. Non-Validated Apple Device Important The devices above are NOT supported by USB interface. Apple does not support digital media transfer from these devices through the USB port. The customer can still listen to their older iPod on vehicle by connecting it to the Auxiliary Input Jack using a standard 3.5 mm (1/8 in) stereo cable. Page 8451 Disclaimer Page 7364 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 7599 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Switch Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the oil pressure switch. 3. Remove the engine oil pressure switch. Installation Procedure Page 10076 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 114 Seat Components - Passenger 1 - Seat Back Cover - Passenger 2 - Heated Seat Element - Passenger Back (KA1) 3 - Seat Back Cushion Pad - Passenger 4 - Seat Belt Switch - Passenger 5 - Seat Horizontal Motor - Passenger (1LZ) 6 - Seat Rear Vertical Motor - Passenger (1LZ) 7 - Heated Seat Control Module - Passenger (KA1) 8 - Seat Front Vertical Motor - Passenger (1LZ) 9 - Heated Seat Switch - Passenger (KA1) 10 - Seat Adjuster Switch - Passenger (1LZ) 11 - Inflatable Restraint Front Passenger Presence System (PPS) Module 12 - Seat Cushion - Passenger 13 - Heated Seat Element - Passenger Cushion (KA1) 14 - Seat Cover - Passenger Page 5772 Fuse Block - Underhood Top View (LAT) Page 8456 Disclaimer Locations Knock Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Lower Front and Rear of the Engine Components (LY7) Page 351 4. Disconnect the engine wiring harness electrical connectors (2) from the ECM. 5. Remove the engine wiring harness clips (3) from the ECM bracket (4). Caution: Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables or when charging the vehicles battery. 6. Gently lift the ECM retainers (1) up, disengaging the retainers from the ECM (2). 7. Tilt the ECM towards the engine and remove the ECM (2) from the bracket. Installation Procedure Page 8284 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Locations Wiper Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Service and Repair Fuel Door: Service and Repair Fuel Tank Filler Door Replacement Page 6057 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors Yazaki Connectors Special Tools J-38125 Terminal Repair Kit Page 1879 Engine Mount: Service and Repair Engine Mount Replacement Engine Mount Replacement Removal Procedure 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 2. Support the engine with a hydraulic floor jack. Use a piece of wood between the floor jack and the oil pan. 3. Remove the engine mount to bracket bolts (1). 4. Remove the engine mount to side rail bolts (2). 5. Remove the engine mount from the engine compartment. Installation Procedure Audio System - USB/Multimedia Interface Information Auxiliary Input / Output Jack: Technical Service Bulletins Audio System - USB/Multimedia Interface Information INFORMATION Bulletin No.: 09-08-44-013C Date: October 05, 2010 Subject: Information on USB Command and Control Multimedia Player Interface/List of Supported Devices Models: 2010-2011 Buick Enclave, LaCrosse 2008-2011 Cadillac CTS 2010-2011 Cadillac Escalade Models, SRX 2009-2010 Chevrolet Cobalt 2009-2011 Chevrolet HHR, Malibu 2010-2011 Chevrolet Avalanche, Camaro, Equinox, Silverado, Suburban, Tahoe, Traverse 2011 Chevrolet Cruze 2010-2011 GMC Acadia, Sierra, Terrain, Yukon 2009-2010 Pontiac G5, G6, Solstice, Solstice Coupe 2009-2010 Saturn AURA, SKY 2010 Saturn OUTLOOK All Equipped with Convenience and Connectivity Package - RPOs KTA, KTB, SRJ, U4H, UUI, UUJ, UUM, UUN, U2S, U2X, U2Y, UAV, UYZ, UY5 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-44-013B (Section 08 - Body and Accessories). USB Radio and MP3 Functionality The USB (Universal Serial Bus) will be a USB 2.0 port on the radio faceplate, on the IP or in the center console. This interface will give the customer the additional functionality of iPod/MP3 command and control. Customers now have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The customer will also have playback capability with a USB memory stick (only MP3 and WMA files). Note Not all memory sticks are supported. Customers have full radio control of the iPod/MP3 audio files via the USB cable. A single USB connection allows digital audio transferring from the iPod to the radio. The iPod will be charging while connected to the radio. Note Video from the iPod is NOT capable of being transferred to a Navigation radio display. For the Chevrolet Cobalt, HHR and Malibu; Pontiac G5, G6, Solstice; and Saturn AURA, SKY, the USB port is on the faceplate of the radio. For all other models, it is located in the center console or IP. For the Cadillac CTS only, a special iPod cable (USB and AUX cable) is needed. This special cable comes delivered with the vehicle. In all cases, the iPod will be charging while connected to the radio through the USB port when the vehicle is running or the RPA is active. Problems with iPod Not Connecting If the infotainment system does not operate properly when using a device connected through the USB port, this may be due to an incompatible media device. Important DO NOT replace the radio or multimedia interface module due to a customer device incompatibility issue. Verify the customer's media device is validated for this system using the list below. If the customer's device is a validated device for this system, follow the SI diagnostic procedure to isolate the fault. If the customer's device is not on the validated device list, explain to the customer that their particular unit is not compatible with the system. Troubleshooting Tips for iPod Devices Page 10062 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Connector Position Assurance Locks Connector Position Assurance Locks Page 6809 Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Page 4539 Shift Solenoid: Specifications 6T70/6T75 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Page 1949 1. If equipped with hydraulic power steering, place the cover over the ball studs, aligning the cover openings with the power steering reservoir cap and oil fill tube opening. 2. Push down on the cover above the studs in order to engage the cover grommets to the studs. 3. If equipped with electric power steering, place the cover over the ball studs, aligning the cover opening with the oil fill tube opening. 4. Push down on the cover above the studs in order to engage the cover grommets to the studs. 5. Install the engine oil fill tube and cap. Page 9600 Page 9898 Page 4616 Transmission Mode Switch: Service and Repair Manual Shift Auxiliary Position Switch Replacement - Steering Wheel Page 4485 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Page 10632 For vehicles repaired under warranty, use the table. Disclaimer Page 2824 Page 4661 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 813 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement Page 8602 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Page 7114 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Page 10376 Page 3729 Automatic Transmission Output Shaft Speed (OSS) Sensor (ME7 or MN5) Page 9874 Page 6615 Relay Box: Locations Fuse Block - Rear Electrical Center Identification Views Fuse Block - Rear Label Page 8079 Seat Belt Retractor: Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Procedures Sunroof / Moonroof Track: Procedures Sunroof Track Timing/Synchronization Removal Procedure 1. Place the module in the full open position. 2. It is only necessary to lower the headliner. Only perform the steps in headliner replacement procedure that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (See: Interior Moulding / Trim/Headliner/Service and Repair).. 3. Disconnect the electrical connector from the motor/actuator. 4. Remove the motor. Refer to Sunroof Motor/Actuator Replacement (See: Sunroof / Moonroof Motor/Service and Repair). 5. Push the window guides rearward on the track until the guides are positioned against the rear hard stop. Installation Procedure 1. Install the motor. Refer to Sunroof Motor/Actuator Replacement (See: Sunroof / Moonroof Motor/Service and Repair). 2. Connect the electrical connector to the motor/actuator. 3. Install the headliner. Refer to Headlining Trim Panel Replacement (See: Interior Moulding / Trim/Headliner/Service and Repair). 4. Perform the Initialization/Teach Procedure. Refer to Sunroof Motor/Actuator Initialization/Teach Process (See: Sunroof / Moonroof Motor/Testing and Inspection). 5. Verify the operation of the sunroof. Page 3092 1. Install the MAF/IAT sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1) and tighten to 2.5 Nm (22 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor (2). Page 2214 8. Install the lower right and left HO2S (1, 2) using the J 39194-B. Tighten the sensors to 42 Nm (31 lb ft). 9. Connect the front engine wiring harness electrical connector (1) to the HO2S electrical connector. 10. Install the lower left HO2S CPA retainer (3). 11. Connect the rear HO2S electrical connector to the engine wiring harness electrical connector (2). 12. Install the lower right HO2S electrical connector CPA retainer (1). 13. Remove the muffler assembly. Refer to Exhaust Muffler Replacement (See: Muffler/Service and Repair). Page 6345 Ignition Coil 4 (LAT or LE5 or LE9) Locations Solar Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 4641 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual Valve Disassembled Views Disassembled Views Case and Associated Parts Page 6550 Fuel Pressure Gauge Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gauge Installation and Removal Fuel Pressure Gauge Installation and Removal Special Tools CH-48027-100 - Digital Pressure Gauge For equivalent regional tools, refer to Special Tools (See: Powertrain Management/Computers and Control Systems/Tools and Equipment). Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Connect the CH-48027-1 - gauge (1) to the CH-48027-2 - adapter (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027-100 - gauge, refer to the manufacture's directions. Removal Procedure Page 1377 Fuse 6 .................................................................................................................................................. ................................................................ Emission Fuse 7 ................................................................. ...................................................................................................................... Left Headlamp Low-Beam Fuse 8 ............................................................................................................................... .......................................................................................... Horn Fuse 9 .............................................. ...................................................................................................................................... Right Headlamp Low-Beam Fuse 10 ............................................................................................................ ........................................................................................ Front Fog Lamps Fuse 11 .......................... .......................................................................................................................................................... Left Headlamp High-Beam Fuse 12 .................................................................................................... .............................................................................. Right Headlamp High-Beam Fuse 13 ................... ........................................................................................................................................................... Engine Control Module BATT Fuse 14 ................................................................................................ .................................................................................................. Windshield Wiper Fuse 15 ................ ............................................................................................................................................................. Antilock Brake System (IGN 1) Fuse 16 .............................................................................................. ................................................................................ Engine Control Module IGN 1 Fuse 17 ............... .............................................................................................................................................................. ........................... Cooling Fan 1 Fuse 18 ............................................................................................ ............................................................................................................ Cooling Fan 2 Fuse 19 .................................................................................................................................. Run Relay, Heating, Ventilation, Air Conditioning Blower Fuse 20 ........................................................................ ................................................................................................................. Body Control Module 1 Fuse 21 ................................................................................................................................................ .......................... Body Control Module Run/Crank Fuse 22 ................................................................ ......................................................................................................................... Rear Electrical Center 1 Fuse 23 ............................................................................................................................................. ............................................ Rear Electrical Center 2 Fuse 24 ........................................................... ............................................................................................................................... Antilock Brake System Fuse 25 ................................................................................................................................... ...................................................... Body Control Module 2 Fuse 26 ................................................... .............................................................................................................................................................. ... Starter Fuse 41 ................................................................................................................................ ......................................................... Electric Power Steering Fuse 42 ............................................... .................................................................................................................... Transmission Control Module Battery Fuse 43 .................................................................................................. Ignition Module (LZ4, LZE, LE9 & LE5); Injectors, Ignition Coils Odd (LY7) Fuse 44 ............................................................................................................. Injectors (LZ4, LZE, LE9 & LE5); Injectors, Ignition Coils Even (LY7) Fuse 45 .................................................................................................................................................... Post Cat 02 Sensor Heaters (LY7, LZ4 & LZE) Fuse 46 ............................................................................. .......................................................................................................... Daytime Running Lamps Fuse 47 ......................................................................................................................................................... ................... Center High-Mounted Stoplamp Fuse 50 ........................................................................ ................................................................................................................... Driver Power Window Fuse 51 ................................................................................................................................................ ................................................................ Not Used Fuse 52 ............................................................... .......................................................................................................................................... AIR Solenoid Fuse 54 ................................................................................................................................. ................................................... Regulated Voltage Control Fuse 55 ................................................ ..................................................................................................................................................... DC/AC Inverter Fuse 56 ...................................................................................................................... ......................................................... Antilock Brake System BATT Relays .................................................................................................................................................. ........................................................................ Usage Relay 28 .............................................................................................................................................. ......................................................... Cooling Fan 1 Relay 29 ............................................................. ..................................................................................................................... Cooling Fan Series/Parallel Relay 30 ...................................................................................................................... ................................................................................. Cooling Fan 2 Relay 31 ..................................... .............................................................................................................................................................. ................ Starter Relay 32 .................................................................................................................. ............................................................................ Run/Crank, Ignition Relay 33 .................................. .............................................................................................................................................................. ............ Powertrain Relay 34 ............................................................................................................... ........................................................................ Air Conditioning Clutch Relay 35 ................................ .............................................................................................................................................................. ............. High Beam Relay 36 .............................................................................................................. .................................................................................... Front Fog Lamps Relay 37 ............................. .............................................................................................................................................................. .......................... Horn Relay 38 ........................................................................................................... ............................................................................... Low-Beam Headlamp Relay 39 ........................... .............................................................................................................................................................. .... Windshield Wiper 1 Relay 40 ......................................................................................................... .................................................................................... Windshield Wiper 2 Relay 48 ......................... ............................................................................................................................................................. Daytime Running Lamps Relay 49 ...................................................................................................... ....................................................................................................... Stoplamps Relay 53 .................... .............................................................................................................................................................. ..................... AIR Solenoid Diodes ................................................................................................................................................. ......................................................................... Usage Relay 27 .............................................................................................................................................. ..................................................................... Wiper Page 37 Disclaimer Page 914 Page 5854 3. Disconnect the seat to body harness connector (1). Disconnect the seat airbag connector (2). Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing into the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Slide the conduit away on the seat airbag harness and remove just enough tape on the body harness to access the wires to install the terminals and seals. Note Use caution when stripping insulation. Take care not to cut through the wire strands. 5. Slide the wire seals onto all four leads back enough to enable removal of the insulation. Install the blue seals (1) on the body harness and the white seals (2) on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Diagrams Seat Heater Switch: Diagrams Component Connector End Views Heated Seat Switch - Driver (KA1) Heated Seat Switch - Passenger (KA1) Page 4058 Seals and Gaskets: Service and Repair 4T45-E - Automatic Transmission Front Wheel Drive Shaft Seal and Output Shaft Sleeve Replacement - Left Side Front Wheel Drive Shaft Seal and Output Shaft Sleeve Replacement - Left Side Special Tools * J 8092 Driver Handle * J 41102-1A Axle Seal Installer * J 41227 Output Shaft Sleeve Remover * J 41228 Output Shaft Sleeve Installer Removal Procedure 1. Raise the vehicle. Support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the left drive axle assembly. Refer to Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement). 3. Remove the snap ring from axle. Discard the snap ring. Do not reuse. Page 6537 X600 Page 9378 Sunroof / Moonroof Panel: Service and Repair Sunroof Window Replacement Removal Procedure 1. Cycle the sunroof window to the vent position. 2. Slide the sunshade to the full rearward position. 3. From inside the vehicle, remove the sunroof window screws on both sides. Note: Do NOT scratch the roof surface or the sunroof window. 4. Lift the sunroof window from the sunroof opening. Installation Procedure Page 6697 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 6022 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Locations Throttle Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left Side of the Instrument Panel Components (1 of 2) 1 - Brake Pedal Position (BPP) Sensor 2 - Accelerator Pedal Position (APP) Sensor 3 - Accelerator Pedal 4 - Brake Pedal Page 5166 Page 2937 Page 10813 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 5879 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 8943 Rear Floor Panel Carpet Replacement Rear Floor Panel Carpet Replacement Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 10523 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 6137 FUSES ................................................................................................................................................. ..................................................................... USAGE POWER MIRRORS ............................................................................................................................. ...................................................... Power Mirrors EPS ....................................................................... .................................................................................................................... Electronic Power Steering RUN/CRANK ......................................................................................................................... Cruise Control Switch, Passenger Airbag Status Indicator HVAC BLOWER HIGH ............................................................................................ Heating Ventilation Air Conditioning Blower - High Speed Relay CLUSTER/THEFT .............................................................................................................................. Instrument Panel Cluster, Theft Deterrent System ONSTAR .......................................................................................... ...................................................................................................................... OnStar NOT INSTALLED ......................................................................................................................................... .................................................... Not Used AIRBAG (IGN) ................................................................ ...................................................................................................................... Airbag (Ignition) HVAC CTRL (BATT) ................................................................... Heating Ventilation Air Conditioning Control Diagnostic Link Connector (Battery) PEDAL .......................................................................... ...................................................................................................................................... Not Used WIPER SW .......................................................................................................................................... ........................ Windshield Wiper/Washer Switch IGN SENSOR ....................................................... ..................................................................................................................................... Ignition Switch STRG WHL ILLUM ............................................................................................................................................................. Steering Wheel Illumination NOT INSTALLED .................................................................................... ......................................................................................................... Not Used RADIO ....................... .............................................................................................................................................................. .................... Audio System INTERIOR LIGHTS ................................................................................. ................................................................................................. Interior Lamps NOT INSTALLED ...... .............................................................................................................................................................. ......................... Not Used POWER WINDOWS .................................................................................. ............................................................................................. Power Windows HVAC CTRL (IGN) .................................................................................................................. Heating Ventilation Air Conditioning Control (Ignition) HVAC BLOWER ........................................................................................................................... Heating Ventilation Air Conditioning Blower Switch DOOR LOCK ..................................................................................... ............................................................................................................. Door Locks ROOF/HEAT SEAT ................................................................................................................................................... ...................... Sunroof, Heated Seat NOT INSTALLED ...................................................................... ....................................................................................................................... Not Used NOT INSTALLED ......................................................................................................................................... .................................................... Not Used AIRBAG (BATT) ............................................................. ....................................................................................................................... Airbag (Battery) SPARE FUSE HOLDER ...................................................................................................................... ................................................ Spare Fuse Holder SPARE FUSE HOLDER ...................................... ................................................................................................................................ Spare Fuse Holder SPARE FUSE HOLDER .......................................................................................................... ............................................................ Spare Fuse Holder SPARE FUSE HOLDER .......................... ............................................................................................................................................ Spare Fuse Holder Page 10025 Page 296 - Select Fuel Composition Reset (F1). - The first parameter is "Fuel Alcohol Content" displayed as a percentage. If the Fuel Alcohol Content percentage is above 25%, this is the probable cause of DTC P0172. - From this screen the "Fuel Alcohol Content" can be reset to zero by pressing the lower right Tech 2(R) button. It will then display 0% when it's reset. Finally, reprogram the PCM with the latest calibration. This will correct for the PCM alcohol calculations. Note The PCM must be reset from this screen. It does not reset to zero when the PCM is reprogrammed. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5433 Electronic Brake Control Module (EBCM) (LY7 or LZ4 or LZE) Page 2475 Page 872 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (ME7 or MN5) Page 7704 Refrigerant: Service and Repair Refrigerant Recovery and Recharging Special Tools * J 43600 ACR 2000 Air Conditioning Service Center * J 45037 A/C Oil Injector Warning To prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. To remove refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers. Warning For personal protection, goggles and lint-free gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Caution: You must replace the desiccant if the A/C refrigerant system has been open to atmosphere for more than four hours, or if the A/C refrigerant oil has been contaminated. Failure to replace the desiccant will result in damage to the A/C refrigerant system. Caution: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. Caution: To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Caution: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. Caution: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Specifications (See: Specifications) for the correct amount. A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Specifications ( See: Specifications). Page 8191 Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor Replacement - Intake Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (7) from the intake camshaft position (CMP) sensor (6). 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. Installation Procedure Page 3925 8. Remove the remaining oil pan bolts and the oil pan. 9. Remove the oil pan gasket. 10. Remove the oil level control valve. 11. Remove the oil filter and oil filter O-ring seal. The seal may stay in case when filter is removed. Page 5771 Page 5689 X304 Inline Harness Connector End Views X304 Body Harness to Console Harness Page 929 Note: Rotate the pigtail 90 degrees from vertical before securing the fastener. 1. Install the knock sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the knock sensor bolt and tighten to 25 Nm (18 lb ft). 3. Install the knock sensor electrical connector pigtail (6) clip to the oil level indicator tube bracket. 4. Connect the engine wiring harness electrical connector (1) to the knock sensor pigtail electrical connector (6). 5. Lower the vehicle. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Page 4764 10. Fill the brake master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 11. Apply and release the park brake lever 4 times. 12. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing (See: Procedures). Page 9783 Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch Page 4744 1. Install the brake caliper bracket. Caution: This is a self-retaining fastener joint that does not require thread locking compounds. Do not attempt to clean the threads with a standard tap. If a standard tap is used, damage to the joint threads will occur. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the brake caliper mounting bracket bolts (2) and tighten to 130 Nm (96 lb ft). 3. Install the brake pad retainers (2) to the brake caliper bracket (3). 4. Install the brake pads (1) to the brake caliper bracket (3). 5. Install the brake caliper. Refer to Rear Brake Caliper Replacement (See: Rear Brake Caliper Replacement). 6. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. Lower the vehicle. 8. Pump the brake pedal 2-3 times in order to seat the rear disc brake pads to the rotor. Page 1715 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement Tools Required J 43631 Ball Joint Separator Removal Procedure 1. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 4. Using the J 43631, release the wheel stud from the bearing hub and discard the stud. Installation Procedure Page 6226 Camshaft Position (CMP) Sensor - Bank 1 Exhaust (LY7) Page 8322 Disclaimer Page 8291 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Page 6173 Fuse Block - Rear Top View Page 5207 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Page 2953 1. Lubricate the NEW MAP sensor seal with clean engine oil. 2. Install the MAP sensor (1) into the intake manifold. 3. Connect the fuel injector wiring harness electrical connector (2) to the number 3 fuel injector. 4. Install the fuel injector wiring harness clips (1) to the fuel rail tabs. Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Page 9390 Head Rest: Service and Repair Rear Seat Head Restraint Guide Replacement Rear Seat Head Restraint Guide Replacement Page 9640 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to auto range to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Page 2924 Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: * Scan tool B+ voltage at terminal 16 * Scan tool ground at terminal 4 * Common ground at terminal 5 Diagnostic Aids * The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. * If the B+ circuit, ground circuits, and connections of the DLC are functioning properly, the malfunction must be due to the scan tool/CANdi module. Reference Information Schematic Reference Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information. Circuit/System Testing 1. Test for less than 2.0 ohms between the ground circuits terminal 4 of the DLC and ground, and terminal 5 of the DLC and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. Page 6501 X100 Engine Harness to Transmission Harness (MN5) Service and Repair Trunk / Liftgate Stop: Service and Repair Rear Compartment Lid Overslam Bumper Replacement Removal Procedure 1. Open the rear compartment. 2. Remove the outer bumper from the compartment lid by twisting the bumper counterclockwise. Installation Procedure 1. Install the outer bumper to the compartment lid by twisting the bumper clockwise. 2. Close the rear compartment. Page 4504 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Component Location Component Location Component Locations 1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear Support Assembly Page 9473 Page 3633 25 - Torque Converter and Support and A/Trans Fluid Pump Housing Assembly 26 - Torque Converter and Differential Housing Bolt 27 - Torque Converter Assembly 28 - Dust Cover Push Pin - Model Dependent 29 - Dust Cover Bolt - Model Dependent 30 - Dust Cover - Model Dependent 31 - Front Differential Carrier Assembly 32 - Input Shaft Thrust Bearing Assembly 33 - A/Trans Case Cover Gasket 34 - A/Trans Case Cover Assembly 35 - A/Trans Case Cover Assembly Bolt Page 155 Page 4460 8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95. 10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body and transmission control module (TCM) assembly (5). Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 12. Remove the control solenoid valve assembly filter plate (6). * Discard the filler plate. It is not reusable. * Inspect the pressure switch manifold seals for damage or contamination. Replace the control solenoid valve assembly as necessary. * Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage around the PCS seals. Replace the upper channel plate as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (1). Page 10479 For vehicles repaired under warranty use the table above. Disclaimer Page 9649 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Page 5493 Heated Oxygen Sensor (HO2S) 2 (LAT or LE5 or LE9) Page 8168 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Page 2387 Page 4899 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Bracket Replacement Brake Pressure Modulator Valve Bracket Replacement Removal Procedure 1. Remove the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement (See: Brake Pressure Modulator Valve Replacement). 2. Remove the BPMV bolt (1). 3. Remove the bracket (1) from the BPMV. Installation Procedure Page 9131 Page 5590 Starter Generator Control Module (SGCM) X3 (LAT) Page 562 Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Locations Fluid Pressure Sensor/Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Diagrams Air Injection Pump: Diagrams Component Connector End Views Secondary Air Injection (AIR) Pump (NU6) Secondary Air Injection (AIR) Pump Solenoid (LE5 with NU6, or LE9 with NU5) Page 8682 Note: Note the number and location of the factory welds for installation of the front impact bar. 6. Locate and drill out all the necessary factory welds. 7. Remove the impact bar. Installation Procedure Page 4980 3. Using needle nose pliers carefully depress the retaining tabs on the end of the brake fluid level sensor. 4. Remove the brake fluid level sensor from the master cylinder. Installation Procedure Exploded Views Shift Solenoid: Exploded Views 6T30/6T40/6T45 - Automatic Transmission Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly Page 7725 Page 4181 5. Remove the park lock cable end (1) from the park lock lever by sliding the cable end reward off the park lock lever pin 6. Release the park lock cable retainer (2) from the shift control base. 7. Remove the transmission shift control nuts (1). 8. Remove the transmission shift control (2). Installation Procedure Page 8358 Digital Video Disc (DVD) Control Module X3 (SPO Accessory) (UJ5) Page 2164 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement - Radiator Outlet Pipe to Engine Coolant Thermostat Housing Pipe Radiator Outlet Hose Replacement - Radiator Outlet Pipe to Engine Coolant Thermostat Housing Pipe Locations Alarm Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 9789 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver (LTZ) Seat Adjuster Switch - Driver (AG1) Page 3183 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Page 9714 Page 7326 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Locations Oxygen Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Lower Front and Rear of the Engine Components (LY7) Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder Replacement Page 9704 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Page 7905 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Page 7650 Heater Hose: Service and Repair Heater Outlet Hose Replacement Heater Outlet Hose Replacement Special Tools J 38185 Hose Clamp Pliers Warning With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. Removal Procedure 1. Partially drain the coolant. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 2. Remove the surge tank from the surge tank bracket. 3. Reposition the heater outlet hose clamp at the heater core using the J 38185. 4. Remove the heater outlet hose from the heater core. Page 819 Page 6409 Speaker - Left Front (UQ3) Speaker - Left Front (UW5) Page 10019 Specifications Spark Plug: Specifications Ignition System Specifications Page 782 Camshaft Position (CMP) Sensor - Intake (LAT or LE5 or LE9) Page 1045 Transmission Speed Sensor: Connector Views Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Output Shaft Speed (OSS) Sensor (MH2 or MH8) Page 10615 Window Switch - Right Rear Page 9355 Sunroof / Moonroof Drain: Removal and Replacement Sunroof Housing Front Drain Hose Replacement Sunroof Housing Front Drain Hose Replacement Removal Procedure 1. It is only necessary to lower the headliner. Only perform the steps in headliner replacement procedure that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (See: Interior Moulding / Trim/Headliner/Service and Repair). 2. Disconnect the front sunroof drain hose from the sunroof drain spigot. 3. Disengage the sunroof drain hose from the attachment points on the windshield pillar. 4. Pull the grommet and a short length of the front drain hose out of the front hinge pillar. 5. Disconnect the grommet from the drain hose. 6. Remove the hose from the vehicle Page 9078 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Page 3278 7. Connect the lower right HO2S electrical connector to the engine wiring harness electrical connector (2). 8. Install the CPA retainer (3). 9. Install the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement (See: Steering and Suspension/Suspension/Stabilizer Bar/Service and Repair/Rear Suspension). 10. Install the muffler assembly. Refer to Exhaust Muffler Replacement (See: Engine, Cooling and Exhaust/Exhaust System/Muffler/Service and Repair). Page 8185 Specifications Camshaft Gear/Sprocket: Specifications Exhaust Camshaft Position Actuator First Pass ............................................................................................................................................. ......................................................... 30 Nm (22 lb ft) Final Pass ........................................................ .................................................................................................................................................... 100 degrees Intake Camshaft Position Actuator First Pass ............................................................................................................................................. ......................................................... 30 Nm (22 lb ft) Final Pass ........................................................ .................................................................................................................................................... 100 degrees Page 2444 1. Lubricate the CKP sensor O-ring seal with clean engine oil. 2. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CKP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 5. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 6. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Page 6609 Procedures Throttle Body: Procedures Throttle Body Cleaning Warning Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. Caution: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate. Caution: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Note: DO NOT prop open the throttle blade with the ignition key in the ON position as it may set a diagnostic trouble code (DTC). 2. Inspect the throttle body bore and the throttle valve plate for deposits. You must open the throttle valve in order to inspect all of the surfaces. 3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with Top Engine Cleaner P/N 1052626 (Canadian P/N 993026), AC Delco(R) P/N X66, or an equivalent product. 4. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 5. Perform the throttle/idle learn procedure. Refer to Throttle/Idle Learn (See: Testing and Inspection/Programming and Relearning/Throttle Learn). Page 2074 Installation Procedure 1. Position a NEW water pump gasket and the water pump to the engine front cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the water pump bolts and tighten to 25 Nm (18 lb ft). 3. Install the water pump pulley and bolts. 4. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 5. Tighten the water pump pulley bolts to 25 Nm (18 lb ft). 6. Fill the cooling system. Refer to Cooling System Draining and Filling (See: Cooling System/Service and Repair/Cooling System Draining and Filling). 7. Inspect for leaks. Page 9964 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ........................................ 345-414 kPa (50-60 psi). Verify the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute Electrical - Various Electrical Concerns/False Messages Door Position Switch: All Technical Service Bulletins Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Page 1723 When lifting the vehicle with a frame-contact lift, place the front lift pads on the front lower brackets, inboard of the rocker pinch weld flange and outboard of the front frame rail, at the torque box location, as shown. Rear Lift Pads When lifting the vehicle with a frame-contact lift, place the rear lift pads on the rear frame rail, at the torque box location, as shown. Vehicle Jacking Caution: When you are jacking the vehicle at the front locations, be certain that the jack or the jack lift pad does not contact the front fascia, front fascia air dam, or the front fenders. If such contact occurs, vehicle damage may result. When jacking at selected front locations additional clearance may be required for the jacking points. Note: When you are lifting a vehicle with a service jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Front of Vehicle When using a service jack under the front of the vehicle use one of the following locations: * Place the service jack pad in the same location as shown for the front lift pads. * Under the front frame crossmember, as shown. Rear of Vehicle Note: Place jackstands ONLY under strong and stable vehicle structures. When using a service jack under the rear of the vehicle place the jack pad on the rocker panel flange, at the torque box location, as shown. 4T45-E - Automatic Transmission Shift Cable: Service and Repair 4T45-E - Automatic Transmission Floor Shift Control Cable Replacement Removal Procedure 1. Set the park brake and chock the wheels. 2. Disconnect the transaxle shift control cable terminal from the transaxle manual shift lever pin. 3. Press the locking tabs (1) inward in order to release the transaxle shift control cable from the cable bracket. 4. Remove the center floor air outlet. Refer to Rear Floor Air Duct Replacement (See: Heating and Air Conditioning/Air Duct/Service and Repair/Rear Floor Air Duct Replacement). 5. Disconnect the transmission range selector lever cable terminal (2) from the shift lever pin. 6. Release the transmission range selector lever cable retainer (1) and remove the transmission range selector cable from the transmission control Page 4084 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement Special Tools J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. Warning A/T Controls - Downshift Hesitation/Delayed Shifting Knock Sensor: Service and Repair Knock Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (1) from the knock sensor pigtail electrical connector (6). 4. Remove the knock sensor electrical connector pigtail (6) clip from the oil level indicator tube bracket. 5. Remove the knock sensor bolt. 6. Remove the knock sensor. Installation Procedure Page 2371 1. Set the ECM (2) into the bottom of the bracket and push the ECM towards the battery until the ECM snaps into place and is secured by the retainers (1). 2. Connect the engine wiring harness electrical connectors (2) to the ECM. 3. Install the engine wiring harness clips (3) to the ECM bracket (4). Service and Repair Connecting Rod Bearing: Service and Repair Piston, Connecting Rod, and Bearing Replacement Special Tools * EN-8037 - Ring Compressor * EN-24270 - Cylinder Bore Ridge Reamer * EN-43966-1 - Connecting Rod Guides * EN-45059 - Angle Meter For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the oil pan. Refer to Oil Pan Replacement (See: Engine Lubrication/Oil Pan/Service and Repair). 2. Remove the cylinder head. Refer to Cylinder Head Replacement (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement ). 3. If a ring ridge is present, remove the ring ridge as follows: 1. Turn the crankshaft until the piston is at the bottom of the stroke. 2. Place a cloth on top of the piston. 3. Use a EN-24270 - reamer to remove the ring ridge. 4. Turn the crankshaft so the piston is at top of the stroke. 5. Remove the cloth and cutting debris. Note: Place the numbers on connecting rods and the connecting rod caps. The connecting rod caps must be assembled to their original connecting rods. Page 6301 Fuel Injector 4 (LAT or LE5 or LE9) Fuel Injector 4 (LY7) Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side Air Duct: Service and Repair Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side Removal Procedure 1. Remove the instrument panel (I/P) assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). 2. Disconnect the wire harness clip at the left air outlet duct. 3. Remove the left air outlet duct screws. 4. Remove the left air outlet duct. Installation Procedure Electrical Specifications Fuel Injector: Electrical Specifications Fuel Injector Resistance ...................................................................................................................... ................................................................ 11-14 ohms Engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F) Page 6131 * Use TXL type wire Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 2879 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Page 232 Locations Parking Brake Release Switch: Locations Instrument Panel/Center Console Component Views Lower Left Side of the Instrument Panel Components (2 of 2) 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Locations Traction Control Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 5652 Automatic Transmission Output Shaft Speed (OSS) Sensor (ME7 or MN5) Automatic Transmission Shift Lever Position Indicator Page 5515 Ignition Coil 3 (LY7) Page 8261 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 2576 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 adapter (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 - adapter (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 - adapter (2). 5. Remove the hose on the CH-48027-2 - adapter (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 - gauge (1) from the CH-48027-2 - adapter (2). 3. Disconnect the CH-48027-2 - adapter (2) from the CH-48027-2 - adapter (3). 4. Disconnect the CH-48027-2 adapter (3) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Install the engine cover, if required. 7. Tighten the fuel fill cap. Page 5601 Tail/Stop and Turn Signal Lamp - Right (without LTZ) Electrical - Various Electrical Concerns/False Messages Door Switch: Customer Interest Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Page 1496 When lifting the vehicle with a frame-contact lift, place the front lift pads on the front lower brackets, inboard of the rocker pinch weld flange and outboard of the front frame rail, at the torque box location, as shown. Rear Lift Pads When lifting the vehicle with a frame-contact lift, place the rear lift pads on the rear frame rail, at the torque box location, as shown. Vehicle Jacking Caution: When you are jacking the vehicle at the front locations, be certain that the jack or the jack lift pad does not contact the front fascia, front fascia air dam, or the front fenders. If such contact occurs, vehicle damage may result. When jacking at selected front locations additional clearance may be required for the jacking points. Note: When you are lifting a vehicle with a service jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support. Front of Vehicle When using a service jack under the front of the vehicle use one of the following locations: * Place the service jack pad in the same location as shown for the front lift pads. * Under the front frame crossmember, as shown. Rear of Vehicle Note: Place jackstands ONLY under strong and stable vehicle structures. When using a service jack under the rear of the vehicle place the jack pad on the rocker panel flange, at the torque box location, as shown. Electrical - Various Electrical Systems Malfunctions Body Control Module: Customer Interest Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Page 8256 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 3370 Fuel: Service Precautions Gasoline/Gasoline Vapors Warning Warning Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. Page 753 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Locations Torque Converter Clutch Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 9136 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Page 2845 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Locations Fluid Pressure Sensor/Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 6483 Backup Lamp - Right Battery (+) X1 Page 5828 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 6458 1-2 Shift - Br Component Connector End Views 1-2 Shift Solenoid (SS) Valve (ME7 or MN5) Page 641 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the engine oil pressure switch. Tighten the switch to 22 Nm (16 lb ft). 2. Connect the engine wiring harness electrical connector (2) to the oil pressure switch. 3. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). Page 744 Hazard Warning Switch: Diagrams Component Connector End Views Hazard Warning Switch Locations Fluid Pressure Sensor/Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 6504 X108 Engine Harness to Body Harness (LE5 or LY7 or LE9) Page 9809 Trunk / Liftgate Switch: Diagrams Component Connector End Views Rear Compartment Lid Release Switch Page 3180 Page 9202 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the MYLAR tape. If the MYLAR tape is damaged, use 3M product AL-36FR to replace the damaged MYLAR tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Page 9669 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wire dress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Engine Controls - MIL ON/DTC P0172 Set Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P0172 Set TECHNICAL Bulletin No.: 10-06-04-004A Date: January 13, 2011 Subject: Intermittent Illumination of Malfunction Indicator Lamp (MIL)/Check Engine Light, DTC P0172 Set (Verify Alcohol Content Information in PCM) Models: 2010 Chevrolet Malibu Equipped with 2.4L 4 Cylinder Engine (VINs B, 0 - RPOs LE5, LE9) Please refer to GWM/IVH Supercede: This bulletin is being revised to update the engine type codes. Please discard Corporate Bulletin Number 10-06-04-004 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an intermittent illumination of the malfunction indicator lamp (MIL)/check engine light. Technicians may find a DTC P0172 set. Correction Use the procedure below to determine if the PCM has the incorrect alcohol content information. 1. Verify the actual measured percentage of alcohol content using the J-44175-A tester. Refer to Alcohol in Fuel Diagnosis in SI. If the actual alcohol is less than 15%, determine the "Fuel Alcohol Content" using the Tech 2(R). 2. Install the Tech 2(R) and build the vehicle as a 2010 and select Powertrain. 3. Build the vehicle with an LE9 engine (even if it has the LE5 engine). - Select Special Functions. - Select Fuel System (F2). Page 8740 Door Latch - Passenger Page 5305 Fuses ................................................................................................................................................... ......................................................................... Usage Fuse 1 .................................................................................................................................................. .......................................... Air Conditioner Clutch Fuse 2 ................................................................... ................................................................................................................... Electronic Throttle Control Fuse 3 .................................................................................................................................................. ................................................................ Not Used Fuse 4 ................................................................. ................................................................................................ Transmission Control Module Ignition 1 Fuse 5 ............................................................................................................................................... ...................................... Mass Airflow Sensor (LY7) Page 2836 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 3011 Body Control Module: Service and Repair Body Control Module Replacement Page 2746 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 5403 Cellular Telephone Microphone (UE1) Center Console Flood Lamp Locations Transmission Position Switch/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components (ME7 or MN5) 1 - Park/Neutral Position (PNP) Switch Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) Page 3269 8. Remove the lower right HO2S electrical connector CPA retainer (1). 9. Disconnect the rear HO2S electrical connector from the engine wiring harness electrical connector (2). 10. Remove the lower left HO2S CPA retainer (3). 11. Disconnect the front engine wiring harness electrical connector (1) from the HO2S electrical connector. Page 2542 Camshaft Position (CMP) Sensor - Intake (LAT or LE5 or LE9) Diagrams Rear Door Latch: Diagrams Component Connector End Views Door Latch - Driver Door Latch - Left Rear Page 10402 Marker Lamp Bulb: Service and Repair Rear Side Marker Lamp Bulb Replacement Rear Side Marker Lamp Bulb Replacement Page 9433 Rear Seat Back Cushion Cover and Pad Replacement Rear Seat Back Cushion Cover and Pad Replacement Removal Procedure 1. Remove the rear seat back. Refer to Rear Seat Back Cushion Replacement (See: Rear Seat Back Cushion Replacement). 2. Remove the rear seat head restraints. Refer to Rear Seat Head Restraint Replacement (See: Head Rest/Service and Repair/Rear Seat Head Restraint Replacement). Page 8462 Accessory Power Outlet - Center Console Page 5794 Page 1216 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Place a drain pan under the oil drain plug. 3. Remove the oil pan drain plug. 4. Allow the oil to drain completely. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the oil pan drain plug and tighten to 25 Nm (18 lb ft). 6. Lower the vehicle. Note: DO NOT use an open end wrench on the hex on top of the oil filter cap. 7. use an oil filter wrench on the outside diameter of the oil filter cap. 8. Remove the oil filter cap and filter. 9. Remove the filter from the cap. Installation Procedure Page 4730 9. Remove the brake hose to caliper bolt from the brake caliper. 10. Remove the brake hose from the brake caliper. 11. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end. 12. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 13. Remove the 2 brake caliper pin bolts. Page 1807 22. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly. 23. Proceed to the next bore sleeve to be trimmed, repeating steps 10-19 if necessary. 24. Install the piston and the connecting rod. Refer to Piston, Connecting Rod, and Bearing Replacement (See: Piston/Service and Repair). Specifications Compression Check: Specifications Engine Compression Test The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Tires - Slight/Mild Edge Feathering Information Tires: Technical Service Bulletins Tires - Slight/Mild Edge Feathering Information INFORMATION Bulletin No.: 07-03-10-008B Date: August 13, 2009 Subject: Information on Slight or Mild Tire Feathering and Recommended Practices (Normal Tire Wear Condition) Models: 2006-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 07-03-10-008A (Section 03 - Suspension). This bulletin provides information regarding the normal tire wear condition of slight or mild tire feathering and recommended practices. If a vehicle comes into a dealership with a concern of slight or mild feathering-type wear on the tires, review with the customer their past tire rotation history. Tires should be rotated every 8,000 to 13,000 km (5,000 to 8,000 mi) for applicable vehicles with tires where a tire rotation is possible or recommended. Refer to Corporate Bulletin Number 05-03-10-015B for information on tire rotation for vehicles with different front/rear tire/wheel sizes. SOME TIRE FEATHERING IS A NORMAL PART OF TIRE WEAR AND THROUGH PROPER TIRE ROTATION AND INFLATION, THIS TIRE WEAR CAN BE MINIMIZED AND TIRE LIFE MAXIMIZED. If the customer has not rotated the tires within the last 8,000 to 13,000 km (5,000 to 8,000 mi), a tire rotation in the modified X-pattern is necessary to clean-up the feathering, rather than placing the vehicle on the alignment machine. Disclaimer Page 8809 Rear Door Striker: Service and Repair Door Striker Anchor Plate Replacement Removal Procedure Note: This procedure covers the removal and installation of the front and the rear door strikers. It will be necessary to remove the following trim when replacing the front or the rear striker. Note: When the striker bolts have been removed, the striker anchor plate will slip down in the door pillar or quarter panel and the trim will need to be removed to gain access. 1. Remove the body lock pillar lower trim. Refer to Body Lock Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Lower Trim Panel Replacement). 2. Remove the lower center pillar trim. 3. Mark the position of the striker with a grease pencil. 4. Remove the screws from the door striker. 5. Remove the striker (2). Installation Procedure Page 3999 Parking Lock Cable: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Park Lock Cable Replacement Removal Procedure 1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 3. Place the transmission shift control lever in the PARK position. 4. Remove the park lock cable end (1) from the park lock lever by sliding the cable end rearward off the park lock lever pin. 5. Release the park lock cable retainer (2) from the shift control base. 6. Remove the knee bolster. Refer to Driver Knee Bolster Panel Replacement (See: Restraint Systems/Knee Diverter/Service and Repair). 7. Turn the ignition key to the RUN position. Page 5528 Inflatable Restraint Side Impact Module - Left Page 2755 Page 1464 Fuse Block - Rear X3 Page 1824 4. Remove the connecting rod nuts and the connecting rod cap. Discard the bolts and nuts. 5. Remove the connecting rod and the piston out of the top of the engine block using the EN-43966-1 - guides. 6. Clean the cylinder bores with hot water and detergent or with a light honing. 7. Swab the bores with the engine oil and a clean, dry cloth. Installation Procedure 1. Coat the following parts with engine oil: * The piston * The piston rings * The cylinder bore * The bearing surfaces 4T45-E - Automatic Transmission Fluid Line/Hose: Service and Repair 4T45-E - Automatic Transmission Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection Removal Procedure Important: Perform the following procedure when removing the retaining rings and cooler lines from the quick connect fittings located on the radiator and/or the transmission. 1. Pull the plastic cap back from the quick connect fitting and down along the cooler line about 5 cm (2 in). 2. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 3. Remove the retaining ring from the quick connect fitting. 4. Discard the retaining ring. 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure Important: * Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. * Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. * Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 1. Install a new retaining ring into the quick connect fitting using the following procedure: Service and Repair Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement Removal Procedure 1. Remove the fuel pump module assembly. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor electrical connector (1). 3. Disengage the locking tab (2) on the fuel level sensor by pushing inward. 4. Remove the fuel level sensor (1) from the alignment feature (2). Installation Procedure Intake Manifold Replacement Intake Manifold: Service and Repair Intake Manifold Replacement Intake Manifold Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (See: Cooling System/Radiator Hose). 3. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator control (TAC). 4. Disconnect the engine wiring harness electrical connector (2) from the generator starter. 5. Disconnect the engine wiring harness electrical connector (4) from the generator starter. 6. Remove the fuel injector wiring harness electrical connector retainer (6) from the generator starter. 7. Disconnect the fuel injector wiring harness electrical connector (7) from the engine wiring harness electrical connector (8). 8. Remove the engine wiring harness clips (5) from the intake manifold. Page 6149 Page 7692 4. Remove the white plug (1) and assure there is no debris in the drain tube and/or plug. If debris exists, pull from the drain tube (do NOT force back into evaporator case) and reinstall the plug. Important Do not get sealer on the heat shield, on the end of, or within the drain tube. 5. Mask off the areas (1, 2) by the HVAC drain using high-quality automotive tape. 6. Apply high tech seam sealer, Kent Industries P/N P10200*, to the front of dash area as shown in figure below. 7. Remove the high quality automotive tape and reposition the heat shield to its normal position. 8. Lower the vehicle. Let the vehicle run with A/C on. 9. Perform a final inspection for the A/C and verify that the system is draining properly. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information This product is currently available from Kent Industries (1-888-YES-KENT). Warranty Information Locations Transmission Mode Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (MH2) 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 7719 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure Note: Refrigerant recovery is not required. 1. Remove the refrigerant pressure sensor wire harness connector. 2. Remove the refrigerant pressure sensor. 3. Remove and discard the O-ring. Installation Procedure 1. Install a new O-ring. Refer to Air Conditioning O-Ring Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning O-Ring Seal Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the refrigerant pressure sensor and tighten to 5 Nm (44 lb in). Page 6601 Fuse Block - Underhood Top View (LAT) Page 9506 Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Switch Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the oil pressure switch. 3. Remove the engine oil pressure switch. Installation Procedure Page 5943 Note DO NOT replace the sensing and diagnostic module (SDM), side sensors or air bag modules. Note Both driver and passenger seats must be repaired when this concern occurs even if only one DTC code is set. The service kit contains sufficient components to repair both seat connectors. Connector Replacement Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above includes harness and connector clips, which are not required in this installation. Replace connectors on both driver and passenger seats, and then reposition the connectors following the steps below. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Note Only use hand tools to remove the seat to floor mounting bolts. If there are any problems with bolt removal, refer to Corporate Bulletin Number 10-08-50-002. 2. Remove the driver's seat to floor mounting bolts. Loosen the seat from the front retainers and tilt it back to expose the underside of the seat. Refer to Front Seat Replacement - Bucket in SI. Page 5538 Kn - Re Component Connector End Views Knock Sensor (KS) (LAT or LE5 or LE9) Service and Repair Power Distribution Relay: Service and Repair Relay Replacement Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 1833 7. Remove the fuel feed line retainers (1, 2) from the engine brackets. 8. Remove the camshaft cover bolts. 9. Remove the camshaft cover. Installation Procedure Page 2209 Catalytic Converter: Service and Repair Catalytic Converter Replacement - Left Side Catalytic Converter Replacement - Left Side Special Tools J 39194-B Heated Oxygen Sensor Wrench Removal Procedure Caution: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. Caution: The use of excessive force may damage the threads in the exhaust manifold/pipe. Note: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S. Note: The HO2S may be difficult to remove when the engine temperature is less than 48°C (120°F) 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 2. Remove the connector position assurance (CPA) retainer (5). 3. Disconnect the engine wiring harness electrical connector (4) from the heated oxygen sensor (HO2S) electrical connector (3). 4. Remove the HO2S electrical connector rosebud clip from the oil level indicator tube tab. Page 828 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) (LAT or LE5 or LE9) Knock Sensor (KS) 1 (LZ4 or LZE or LY7) Page 916 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor. Installation Procedure Page 10590 Window Switch - Left Rear Page 995 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. 6T30/6T40/6T45 - Automatic Transmission Transmission Pressure Test Port: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Automatic Transmission Fluid Pressure Test Hole Plug Replacement Page 5457 Engine Control Module (ECM) X3 (LY7) Page 5666 Page 1283 Note: Start all of the nuts and bolts by hand before finalizing any of the torques. 1. Install the NEW steering gear oil seals (1) to the steering gear using the J-44586 remover/installer (2). 2. Ensure the steering gear oil seals (1) are fully seated in the steering gear. Caution: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 3. Position the power steering gear outlet hose to the vehicle. 4. Install the steering gear. Refer to Steering Gear Replacement (See: Steering and Suspension/Steering/Steering Gear/Service and Repair/Steering Gear Replacement). Locations Torque Converter Clutch Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 6944 Page 5561 Rear Window Defogger Grid X2 Recirculation Actuator (C60) Page 3550 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 5608 Transmission Control Module (TCM) (MN5 with LE5 or LE9) Page 9863 Page 7718 Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Refrigerant Pressure Sensor Page 5504 Horn Assembly Air Inlet Grille Panel Replacement Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Air Inlet Grille Panel Replacement Page 10059 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Engine Controls - MIL ON/DTC P0172 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0172 Set TECHNICAL Bulletin No.: 10-06-04-004A Date: January 13, 2011 Subject: Intermittent Illumination of Malfunction Indicator Lamp (MIL)/Check Engine Light, DTC P0172 Set (Verify Alcohol Content Information in PCM) Models: 2010 Chevrolet Malibu Equipped with 2.4L 4 Cylinder Engine (VINs B, 0 - RPOs LE5, LE9) Please refer to GWM/IVH Supercede: This bulletin is being revised to update the engine type codes. Please discard Corporate Bulletin Number 10-06-04-004 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an intermittent illumination of the malfunction indicator lamp (MIL)/check engine light. Technicians may find a DTC P0172 set. Correction Use the procedure below to determine if the PCM has the incorrect alcohol content information. 1. Verify the actual measured percentage of alcohol content using the J-44175-A tester. Refer to Alcohol in Fuel Diagnosis in SI. If the actual alcohol is less than 15%, determine the "Fuel Alcohol Content" using the Tech 2(R). 2. Install the Tech 2(R) and build the vehicle as a 2010 and select Powertrain. 3. Build the vehicle with an LE9 engine (even if it has the LE5 engine). - Select Special Functions. - Select Fuel System (F2). Page 4342 10. Install the control valve body bolt (6) M6 x 55. 11. Install the 3 control valve body bolts (2) M6 x 95. 12. Install the control valve body bolt (3) M6 x 42. 13. Install the 2 control valve body bolts (4) M6 x 65. 14. Connect the input speed sensor electrical connector (1). 15. Connect the output speed sensor electrical connector (2). 16. Connect the shift position switch electrical connector (3). 17. Install the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Control Valve Body Cover Replacement). 18. For transmission control module programming and setup. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Note: After an internal transmission repair or internal part replacement the service fast learn adapt procedure should be performed. 19. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See: Testing and Inspection/Programming and Relearning/6T70/6T75 - Automatic Transmission). Page 5540 License Lamp Main Contactor Relay (HP7) X1 Rear Side Door Window Switch Replacement Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement Rear Side Door Window Switch Replacement Page 6972 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Page 9979 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Locations Transmission Control System Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 6384 Pressure Control (PC) Solenoid Valve (MN5) Page 8255 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 9182 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Page 2872 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 9525 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Connector Position Assurance Locks Connector Position Assurance Locks Page 7044 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the NEW GREY intermediate steering shaft bolt. * For electronic power steering, tighten the bolt to 49 Nm (36 lb ft). * For hydraulic power steering, tighten the bolt to 62 Nm (46 lb ft). 6. Install the left side instrument panel insulator. Refer to Instrument Panel Insulator Replacement Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 7. Connect the intermediate steering shaft to the steering gear. 8. Install the NEW BLACK intermediate steering shaft lower bolt and tighten to 49 Nm (36 lb ft). 9. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 10. Remove the J-42640 - pin from the steering column. Front Side Door Bottom Auxiliary Sealing Strip Replacement Front Door Weatherstrip: Service and Repair Front Side Door Bottom Auxiliary Sealing Strip Replacement Front Side Door Bottom Auxiliary Sealing Strip Replacement Page 312 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 10388 Horn Switch: Service and Repair Steering Wheel Horn Contact Replacement Page 4937 Brake Booster Vacuum Sensor: Diagrams Component Connector End Views Brake Booster Vacuum Sensor (LAT) Locations Transmission Speed Sensor: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH2) Page 6492 Body Control Module (BCM) X3 Page 7736 Control Module HVAC: Diagrams Component Connector End Views Blower Motor Control Module (C68) Page 8663 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Page 5224 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 4137 13 - Front Differential Transfer Driven Gear 14 - Front Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual Valve Disassembled Views Disassembled Views Case and Associated Parts Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Page 4100 25 - A/Trans Fluid Pump Seal Assembly 26 - Torque Converter with Fluid Pump Housing Assembly 27 - Torque Converter and Differential Housing Bolt 28 - A/Trans Fluid Fill Tube Plug Assembly 29 - Torque Converter Assembly Component Location Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear Page 9140 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Page 3804 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Component Location Component Location Component Locations 1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid Pump Drive Link Assembly 12 - Park Pawl Page 1411 Fuse Block - Underhood X4 Page 8589 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 5708 X600 Page 6231 Camshaft Position (CMP) Sensor - Intake (LAT or LE5 or LE9) Page 4462 Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover Replacement). 13. If a NEW TCM has been installed into the vehicle, the NEW module needs to be reprogrammed. Refer to Service Programming System (SPS) ( See: Testing and Inspection/Programming and Relearning/Service Programming System (SPS)). Note: The Service Fast Learn Adapts procedure must be performed when one of the following repairs have been made to the vehicle. Failure to perform the procedure after one of the following repairs may result in poor transmission performance, as well as transmission DTCs being set: * Transmission internal service/overhaul * Valve body repair or replacement * Control solenoid valve assembly replacement * TCM software/calibration update * Any service in response to a shift quality concern 14. Perform the Service Fast Learn Adapts. Refer to Service Fast Learn Adapts (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning/6T70/6T75 - Automatic Transmission). Page 4913 6. Remove the plastic retainer clips (1) from the body, if equipped. 7. Remove the cable from the bracket (1), if equipped. 8. Remove the plastic retainer clip (2) from the body. 9. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 10. Remove the rear park brake cable retainer bolt (1). Page 1901 1. Install the NEW oil filter to the cap. 2. Install the oil filter cap and filter. Caution: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. Note: DO NOT use an open end wrench on the hex on top of the oil filter cap. 3. use an oil filter wrench on the outside diameter of the oil filter cap. Tighten the oil filter cap until fully seated. DO NOT exceed 25 Nm (18 lb ft). 4. Fill the engine with oil. Refer to Fluid and Lubricant Recommendations (See: Maintenance). Page 9586 Page 4211 7. Install the transmission range selector lever cable (3) to the cable bracket (4). 8. Install the retainer (2) to the transmission range selector lever cable. 9. Connect the transmission range selector lever cable terminal (1) to the transmission manual shift lever pin (5). 10. Adjust the automatic transmission range selector lever cable. Refer to Range Selector Lever Cable Adjustment (See: Adjustments/6T70/6T75 Automatic Transmission). Range Selector Lever Cable Bracket Replacement Range Selector Lever Cable Bracket Replacement Page 2648 Disclaimer Page 5183 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Page 7881 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Passenger Door Components Page 10077 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 10065 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 9207 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 9316 Sun Shade: Service and Repair Sunroof Sunshade Stop Replacement Sunroof Sunshade Stop Replacement Removal Procedure 1. It is only necessary to lower the headliner. Only perform the steps in headliner replacement procedure that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (See: Interior Moulding / Trim/Headliner/Service and Repair). 2. Pull the sunshade stop from the sunroof cable drive tube retainer. Carefully scrape off any remaining foam. 3. Use a clean rag and 3M(TM) General Purpose Adhesive Cleaner 08984 or equivalent, in order to remove any adhesive or residue from the sunshade track. Installation Procedure 1. Remove the backing paper from the sunshade stop to expose the adhesive surface. Page 9991 ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Ignition ON, test for B+ between the B+ circuit terminal 4 and ground. ‹› If less than the specified value, test the circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the BCM. 4. Test for B+ between the B+ circuit terminal 4 and the signal circuit terminal 5. ‹› If less than the specified value, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the BCM. 5. Ignition OFF, disconnect the X2 harness connector at the BCM. 6. Test for infinite resistance between the signal circuit terminal 61 and ground. ‹› If less than the specified value, test the signal circuit for a short to ground. 7. If all circuits test normal, test or replace the steering wheel controls switch - left. Component Testing 1. Disconnect the harness connector at the turn steering wheel control switch - left. 2. Cruise control switch ON, measure the resistance between terminal 4 and terminal 5 while individually activating and holding each cruise control function switch and compare the resistance reading to the values in the table below. ‹› If not within the specified resistance range, replace the steering wheel control switch - left. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Steering Wheel Control Switch Assembly Replacement (See: Accessories and Optional Equipment/Sensors and Switches - Accessories and Optional Equipment/Steering Mounted Controls Assembly/Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning) for BCM replacement, setup, and programming Page 6407 Secondary Air Injection (AIR) Pump Solenoid Bank 1 (LZ4 with NU6, or LZE with NU1 or NU5) Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 9930 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Bosch Connectors Bosch Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 9952 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors Tyco/AMP Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 125 Sunroof / Moonroof Module: Diagrams Component Connector End Views Sunroof Control Module (CF5) Page 1906 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Place a drain pan under the oil drain plug. 3. Remove the oil pan drain plug. 4. Allow the oil to drain completely. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the oil pan drain plug and tighten to 25 Nm (18 lb ft). 6. Lower the vehicle. Note: DO NOT use an open end wrench on the hex on top of the oil filter cap. 7. use an oil filter wrench on the outside diameter of the oil filter cap. 8. Remove the oil filter cap and filter. 9. Remove the filter from the cap. Installation Procedure Page 8094 Seat Belt Tensioner: Removal and Replacement Seat Belt Retractor Pretensioner Replacement - Front Page 23 Disclaimer Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Page 627 Page 6290 Engine Coolant Temperature (ECT) Sensor (LZ4 or LZE) Engine Cooling Fan - Left Page 5742 Fuse Block - Underhood Top View (LY7) Specifications Engine Oil Pressure: Specifications Oil Pressure Minimum - @1000 RPM @ 90°C (194°F) ........................................................................................................................... 206.84-482.63 kPa (30-70 psi) Page 6913 9. Remove the power steering gear inlet hose bolt (1) and disconnect the power steering gear inlet hose (2) and the power steering gear outlet hose (4) from the steering gear (3). 10. Remove the power steering gear outlet hose from the vehicle. 11. Extract the steering gear oil seals (1) from the steering gear using J-44586 - remover/installer (2) with the aid of a flat-bladed tool (3) for additional leverage. Installation Procedure Page 3477 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor (2). 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2). Installation Procedure Page 8138 Antenna Cable: Service and Repair Digital Radio Antenna Cable Replacement Digital Radio Antenna Cable Replacement Removal Procedure 1. Lower the headliner with wiring harness attached. Refer to Headlining Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). 2. Remove the rear window shelf panel. Refer to Rear Window Shelf Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Shelf Trim Panel Replacement). 3. Remove the coaxial cable from the front roof bow. 4. Remove the coaxial cable from the inner body side. Page 8177 Page 8518 Speaker: Service and Repair Front Upper Speaker Replacement Front Upper Speaker Replacement Page 10085 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Door Lock Switch Replacement - Driver Door Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Driver Door Door Lock Switch Replacement - Driver Door Page 9966 crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. Electrical - Various Electrical Concerns/False Messages Door Switch: Customer Interest Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Locations Hood Sensor/Switch (For Alarm): Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (2 of 2) 1 - Hood Ajar Switch (AP3) Page 4675 8. Disconnect the left front brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 9. Disconnect the master cylinder primary brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination. Page 2261 Special Tools J-45059 - Angle Meter Removal Procedure 1. If equipped with a 2.4L engine remove the exhaust manifold pipe. Refer to Catalytic Converter Replacement (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement) or Exhaust Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Pipe Replacement). 2. If equipped with a 3.5L or 3.6L engine, remove the catalytic converters. Refer to Catalytic Converter Replacement - Left Side (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Left Side) and Catalytic Converter Replacement - Right Side (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Right Side). 3. Separate the first two muffler insulators from the hangers and support the muffler pipe. 4. Remove the left frame bolts (4). 5. Remove the left frame reinforcement (3). 6. Remove the heat shield nuts. Page 8808 5. Move the striker to eliminate drag on the striker and door latch and to achieve proper door position within door opening. Start with up/down position, then position the striker to achieve proper alignment to the door opening. Set the in/out adjustment for proper door seal engagement ensuring that the door closing efforts are correct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Adjust the striker and add spacers as required. Tighten the screws to 20 Nm (15 lb ft). 7. Inspect the door for proper operation. 8. Close the door. Page 2967 Heated Oxygen Sensor (HO2S) 1 (LAT or LE5 or LE9 with MN5) Heated Oxygen Sensor (HO2S) 1 (LE5 or LE9 with MH8) Page 10485 - Select Fuel Composition Reset (F1). - The first parameter is "Fuel Alcohol Content" displayed as a percentage. If the Fuel Alcohol Content percentage is above 25%, this is the probable cause of DTC P0172. - From this screen the "Fuel Alcohol Content" can be reset to zero by pressing the lower right Tech 2(R) button. It will then display 0% when it's reset. Finally, reprogram the PCM with the latest calibration. This will correct for the PCM alcohol calculations. Note The PCM must be reset from this screen. It does not reset to zero when the PCM is reprogrammed. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 2878 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 8279 If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the Page 6199 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 4816 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent, fluid tank valve, then disconnect the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent, from the J-35589-A - Master Cylinder Bleeder Adapter. 23. Remove the J-35589-A - Master Cylinder Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. Note: If it is determined that air was induced into the system upstream of the ABS modulator prior to servicing, the Antilock Brake System Automated Bleed (See: Antilock Brake System Automated Bleed) must be performed. 26. If the brake pedal feels spongy, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed (See: Antilock Brake System Automated Bleed). 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Page 3470 Page 6921 Power Steering Motor: Service and Repair Power Steering Assist Motor Replacement Removal Procedure 1. Disconnect the power steering assist motor sensor wire harness connector (6) from the power steering assist motor (5). Note: If you are replacing the power steering assist motor, you will need the power steering assist motor sensor wire harness strap clip (7) for the new power steering assist motor installation. If you are replacing the steering column, a new power steering assist motor sensor wire harness strap clip will come with the column service kit. Keep the existing wire strap clip attached to the power steering assist motor sensor wire harness. 2. Use needle nose pliers in order to remove the power steering assist motor wire strap clip from the power steering assist motor. If you are replacing the power steering assist motor, remove the power steering assist motor wire strap clip from the power steering assist motor sensor wire harness. If you are replacing the steering column, keep the power steering assist motor wire harness strap clip attached to the power steering assist motor sensor wire harness. 3. Use a M6x1 TORX(R) head bit in order to remove the 2 power steering assist motor bolts (2). Note: The power steering assist motor housing must be free of any type of debris. Remove any loose debris from the power steering assist motor housing, but do NOT remove the remaining grease on the power steering assist motor input shaft (3). 4. Grasp the power steering assist motor. Pull on the power steering assist motor evenly and straight away from the steering column in order to remove the power steering assist motor. 5. Inspect the steering column assist mechanism input shaft for the rotor isolator bumper (4). If present, remove the rotor isolator bumper. Installation Procedure Note: Before installing the power steering assist motor (2), verify the rotor isolator bumper (1) is installed into the rotor isolator (3) in the power steering assist motor (2). 1. Insert the rotor isolator bumper (1) into the rotor isolator (3) in the power steering assist motor (2). Caution: Do NOT allow the wiring harness to be pinched between the motor/module assembly and the steering column during installation. A pinched harness will cause diagnostic trouble codes to be set and may require replacement of the steering column. 2. Fit the rotor isolator over the steering column assist mechanism input shaft. Locations Combination Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 6188 1 - Fuse Block - Rear Page 3890 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 1255 5. Install the liquid line and compressor hose to the condenser. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the liquid line and compressor hose bolt to the condenser and tighten to 20 Nm (15 lb ft). 7. Install the liquid line to the rail clip. Page 2491 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY7 or LZ4 or LZE) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LY7 or LZ4 or LZE) Page 657 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Duct Air Temperature Sensor Replacement - Lower Removal Procedure 1. Remove the right front floor console extension panel. Refer to Front Floor Console Extension Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Extension Panel Replacement - Right Side). 2. Twist and pull the lower air temperature sensor from the center floor air outlet duct. 3. Remove the lower air temperature sensor wire harness. Installation Procedure 1. Install the lower air temperature sensor wire harness. Page 10095 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Page 4331 8. Install the remaining control valve body bolts. 9. Hand start the bolts and tighten to 12 Nm (9 lb ft). Capacity Specifications Fluid - A/T: Capacity Specifications TRANSMISSION FLUID CAPACITY 4T45-E Bottom Pan Removal .............................................................................................................. .............................................................. 6.6 liters (7.0 quarts) Complete Overhaul ............................. .................................................................................................................................................. 9.0 liters (9.5 quarts) Dry ........................................................................................................................... ......................................................................... 12.2 liters (12.9 quarts) 6T40 / 6T45 Valve Body Cover Removal ..................................................................................................................................................... 5.0-7.0 liters (5.3-7.4 quarts) Fluid Change - Drain Plug ....................................................................................................................................................... 4.0-6.0 liters (4.2- 6.3 quarts) Overhaul ............................................................................................... .................................................................................... 8.0-8.5 liters (8.5-9.0 quarts) 6T70 / 6T75 Valve Body Cover Removal ..................................................................................................................................................... 5.0-7.0 liters (5.3-7.4 quarts) Fluid Change - Drain Plug ....................................................................................................................................................... 4.0-6.0 liters (4.2- 6.3 quarts) Overhaul ............................................................................................... .................................................................................... 7.0-9.0 liters (7.4-9.5 quarts) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 4748 11. Install the brake caliper to the vehicle. Refer to Front Brake Caliper Replacement (See: Removal and Replacement/Front Brake Caliper Replacement). Rear Brake Caliper Overhaul Rear Brake Caliper Overhaul Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Remove the rear brake caliper from vehicle. Refer to Rear Brake Caliper Replacement (See: Removal and Replacement/Rear Brake Caliper Replacement). Note: If the brake caliper was leaking brake fluid from the REAR of the caliper past the integral park brake actuator shaft seal, replace the brake caliper assembly. The park brake integral mechanism contains a non-serviceable seal which may be allowing brake fluid to leak past it and into the non-serviceable integral park brake mechanism. 2. Drain the brake fluid from the caliper assembly. 3. Using a small wooden or plastic tool, carefully remove the brake caliper piston dust boot seal retaining ring from the groove in the caliper seal counterbore. 4. Place a block of wood against the inside of the caliper body, opposite of the caliper piston. 5. Direct low pressure compressed air through the caliper inlet hose to remove the caliper piston. Page 7914 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. Page 8082 Seat Belt Retractor: Service and Repair Rear Seat Center Retractor Side Belt Replacement Rear Seat Center Retractor Side Belt Replacement Page 1759 6. Install the camshaft bearing caps. Hand tighten the cap bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Tighten the bearing cap bolts in increments of 3 turns until they are seated. Tighten the bolts to 10 Nm (89 lb in). 8. Install the exhaust camshaft position actuator. Refer to Camshaft Position Exhaust Actuator Replacement (See: Camshaft Position Exhaust Actuator Replacement). Page 10725 Note: Use care when removing the window not to cut off the locator pins on the left and right sides. If the locating pins are cut off it will be necessary to use masking tape to tape the window in place until the auto-adhesive cures. Note: Keep the cutting edge of the tool against the window. 9. Remove the window from the urethane adhesive. * Leave a base of urethane approximately 2 mm (0.078 in) on the pinch-weld flange. * The only suitable lubrication is clear water. * BO-24402-A - Glass Sealant Remover (Cold Knife). * BO-39032 - Stationary Glass Removal Tool, or equivalent in order to remove the window. Note: Keep the cutting edge of the appropriate tool against the window. Do this from inside the vehicle. 10. If necessary, use the appropriate tool to remove the bottom corners of the windshield from the urethane adhesive. 11. Remove the windshield from the vehicle with an assistant. Installation Procedure 1. Install the windshield into the opening with an assistant. Refer to Adhesive Installation of Stationary Windows (See: Windows/Service and Repair/Removal and Replacement/Adhesive Installation of Stationary Windows). 2. Install the rearview mirror. Refer to Inside Rearview Mirror Replacement (See: Body and Frame/Mirrors/Service and Repair/Inside Rearview Mirror Replacement). 3. Install the remote control door lock receiver. Refer to Remote Control Door Lock Receiver Replacement (See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Module/Service and Repair). 4. Install the interior windshield pillar garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Page 1600 Note: Do not install the repair unit in this step. 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Page 2680 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (7) to the intake CMP sensor (6). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 9591 Page 6622 Fuse Block - Rear X3 Electrical - Various Electrical Systems Malfunctions Wiring Harness: All Technical Service Bulletins Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Page 6621 Fuse Block - Rear X2 Page 8263 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Diagram Information and Instructions Information Bus: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Page 3828 Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (MN5) Page 6477 Automatic Transmission Input Shaft Speed (ISS) Sensor Page 5569 Seat Belt Retractor Pretensioner - Driver Seat Belt Retractor Pretensioner - Passenger Service and Repair Backup Light Bulb: Service and Repair Backup Lamp Bulb Replacement Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Page 532 1 - Outside Rearview Mirror - Passenger 2 - Door Frame 3 - Door Latch - Passenger 4 - Inflatable Restraint Side Impact Sensor (SIS) - Right 5 - Window Switch - Passenger 6 - Speaker - Right Front 7 - Window Motor - Passenger 8 - Door Lock Switch - Passenger 9 - Courtesy Lamp - Right Front Door Page 754 Turn Signal Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Page 3582 1. Lubricate the CKP sensor O-ring seal with clean engine oil. 2. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CKP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 5. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 6. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Page 2094 8. Remove the coolant air bleed hose/pipe from the engine. Installation Procedure 1. Install the coolant air bleed hose/pipe to the engine. 2. Install the coolant air bleed hose to the water outlet. 3. Position the coolant air bleed hose clamp (2) at the water outlet. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the coolant air bleed hose/pipe bolt (3) to the upper intake manifold and tighten to 10 Nm (89 lb in). 5. Position the fuel feed line and install the fuel feed line clip to the stud. 6. Install the fuel feed pipe line nut (2) and tighten to 10 Nm (89 lb in). 7. Install the surge tank inlet hose. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement (See: Coolant Reservoir/Service and Repair/Radiator Surge Tank Inlet Hose/Pipe Replacement). 8. Install the intake manifold cover. Refer to Fuel Injector Sight Shield Replacement (). Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Page 7270 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 1281 6. Remove the 2 power steering gear outlet pipe hose retainers (1) from the right side of the front frame. 7. Remove the 2 power steering gear outlet hose retainers from the front of the front frame. 8. Remove the steering gear. Refer to Steering Gear Replacement (See: Steering and Suspension/Steering/Steering Gear/Service and Repair/Steering Gear Replacement). Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 717 Combination Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Page 5335 Page 10774 7. Remove the solvent container washer hose from the washer solvent container. Installation Procedure 1. Connect the solvent container washer hose (1) to the washer pump (2). 2. Install the solvent container washer hose to the washer solvent container. Ensure that the hose is routed within the channel on the side of the washer solvent container and snapped into the retaining features on the container. 3. Route the hoses upward and into the solvent container clips. 4. Connect the washer hose and electrical harness to the washer pump. 5. Install the front wheelhouse panel splash shield. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 6. Connect the solvent container washer hose (1) to the windshield washer hose (2). 7. Fill the washer solvent container with washer solvent. 8. Close the hood. 9. Inspect the washers for proper operation. Service and Repair Control Arm Bushing: Service and Repair Front Lower Control Arm Bushing Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the lower control arm. Refer to Lower Control Arm Replacement (See: Service and Repair/Front Suspension). 4. Remove the lower control arm to rear bushing bolt. 5. Note the position of the bushing during removal. Remove the bushing off the lower control arm. Installation Procedure Page 8683 Note: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces as necessary. 3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair (). 4. Position the impact bar on the vehicle using 3-dimensional measuring equipment. Clamp the tie bar into place. Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor Replacement - Intake Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (7) from the intake camshaft position (CMP) sensor (6). 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. Installation Procedure Page 3875 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the intermediate/4th band servo piston spring, the servo and the servo cover bolts. Tighten the bolts to 12 Nm (106 lb in). 2. Install the filter and the pan. Refer to Automatic Transmission Fluid Filter and Seal Replacement (See: Fluid Filter - A/T/Service and Repair). 3. Lower the vehicle. 4. Fill the transmission with DEXRON(R) VI fluid. 5. Inspect the transmission oil level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Symptom Related Diagnostic Procedures/4T45-E - Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, the engine control module (ECM), powertrain control module (PCM) or transmission control module (TCM) will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 6. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and Operation/4T45-E - Automatic Transmission/Transmission Adaptive Functions). Page 88 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 1738 Turn Signal Switch Bracket Replacement Turn Signal Switch: Service and Repair Turn Signal Switch Bracket Replacement Turn Signal Switch Bracket Replacement Page 4818 brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (See: Hydraulic Brake System Bleeding). Page 4740 6. If any of the conditions listed are found, the disc brake pad retainers require replacement. 7. Remove the brake caliper mounting bracket bolts (1). 8. Remove the brake caliper bracket from the steering knuckle. 9. Inspect the caliper bracket (5). If the brake caliper bracket (5) is bent, cracked, or damaged, it requires replacement. 10. Inspect the brake caliper guide pins (2) for freedom of movement, and inspect the condition of the guide pin boots (4). Move the brake caliper guide pins (2) inboard and outboard within the brake caliper bracket (5), without disengaging the slides from the boots, and observe for the following: * Restricted caliper guide pin movement * Looseness in the brake caliper mounting bracket * Seized or binding caliper guide pins * Split or torn boots 11. If any of the conditions listed are found, the brake caliper guide pins (2) and/or boots (4) require replacement. Page 1229 13. Remove the coolant crossover pipe bolts (1-4). 14. Remove the coolant crossover pipe. Installation Procedure 1. Position the coolant crossover pipe to the cylinder heads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the coolant crossover pipe bolts (1-4) and tighten to 50 Nm (37 lb ft). Page 1444 Fuse Block - Underhood Top View (LE5 or LE9) Page 4083 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (ME7 or MN5) Page 3610 Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (MN5) Page 7962 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. 2008 Model Year Buick Enclave, GMC Acadia and Saturn OUTLOOK Vehicles Only Note The seat mounted side impact airbag connection to the body harness is located at the forward edge of the seat, below the plastic trim. The connectors are yellow. The body harness wires are exposed - running forward in the vehicle, down through the carpet cutout in the floor. Page 9199 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Page 2024 Page 9437 9. Remove the rear seat back bolts. 10. Remove the rear seat backs from the rear seat back frame. 11. Remove the rear seat back frame from the vehicle. Installation Procedure 1. Install the rear seat back frame into the vehicle. 2. Install the rear seat backs to the rear seat back frame. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the rear seat back to seat back frame bolts and tighten to 35 Nm (26 lb ft). Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 9580 Page 4289 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Electronic Components (MH8) Page 5780 Locations Seat Belt Buckle Switch: Locations Passenger Compartment/Roof Component Views Seat Components - Driver 1 - Seat Back Cover - Driver 2 - Heated Seat Element - Driver Back (KA1) 3 - Seat Back Cushion Pad - Driver 4 - Seat Recline Motor - Driver (1LZ) 5 - Seat Horizontal Motor - Driver (AG1 or 1LZ) 6 - Seat Rear Vertical Motor - Driver (AG1 or 1LZ) 7 - Heated Seat Control Module - Driver (KA1) 8 Seat Front Vertical Motor - Driver (AG1 or 1LZ) 9 - Seat Recline Switch - Driver (1LZ) 10 - Seat Adjuster Switch - Driver 11 - Seat Belt Switch - Driver 12 - Seat Cushion - Driver 13 - Heated Seat Element - Driver Cushion (KA1) 14 - Seat Cover - Driver Seat Components - Passenger Page 9106 Page 9686 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Page 9449 Disclaimer Page 7003 4. Remove the boot clamp (1) from the rack and pinion boot with side cutters. 5. Discard the boot clamp (1). Important: * If a breather tube is present, mark the location of the breather tube on the gear assembly before removal of the rack and pinion boot. * After removing the boot, inspect the inner tie rod for evidence of corrosion or contamination. If none is evident, continue with the repair. If corrosion or contamination is evident, replace the steering gear. 6. Remove the rack and pinion boot (1) and the breather tube, if present, from the rack and pinion gear assembly. Assembly Procedure 1. Install the new boot clamp (1) onto the rack and pinion boot (3). 2. Prior to rack and pinion boot installation, apply grease to the inner tie rod assembly (2) and the rack and pinion gear assembly (1). 3. Install the rack and pinion boot (3) onto the inner tie rod assembly (2). 4. If present, install the breather tube while aligning the breather tube with the mark made during removal and the molded nipple of the rack and pinion boot. Page 5675 X108 Engine Harness to Body Harness (LE5 or LY7 or LE9) Page 10558 Page 3945 Fluid Line/Hose: Service and Repair 6T70/6T75 - Automatic Transmission Transmission Fluid Cooler Pipe Connector Replacement - Radiator Transmission Fluid Cooler Pipe Connector Replacement - Radiator Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 2. Remove the transaxle oil cooler hoses from the oil cooler fittings on the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (See: 6T30/6T40/6T45 - Automatic Transmission/Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection). Note: Do not remove the upper and lower transaxle oil cooler fittings from the radiator at the same time other wise the transaxle oil cooler will fall inside the radiator end tank. 3. Remove the oil cooler fitting from the radiator. Installation Procedure 1. Inspect the new O-ring seals for cracks, cuts or damage. Replace if necessary. Page 4066 Note: Carefully guide the axle shaft past the lip seal. Do not allow the shaft splines to contact any portion of the seal lip surface, otherwise damage to the seal will occur. 10. Install the stub shaft into the transmission. Use a mallet to fully seat the shaft. 11. Install the drive axle assembly. Refer to Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement). 12. Lower the vehicle. 13. Inspect the oil level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Symptom Related Diagnostic Procedures/4T45-E - Automatic Transmission/Transmission Fluid Level and Condition Check). 14. Inspect the shaft and the seal for leaks. Page 7913 "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN(s) 19118426 and 20968489 will not be eligible for RIM management. * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Service Procedure Replace Wire Harness Connector 2010 Chevrolet Malibu and 2010 Pontiac G6 Tools Required - J 38125-7 Crimp Tool - J 38125-6 Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Seat shown out-of-vehicle for illustration purposed Page 3527 1. Lubricate the CKP sensor O-ring seal with clean engine oil. 2. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CKP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 5. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 6. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Page 5488 Headlamp - Left Low Beam Headlamp - Right High Beam Page 9107 Page 5370 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 9570 same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 7116 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Locations Seat Heater Control Module: Locations Passenger Compartment/Roof Component Views Seat Components - Driver 1 - Seat Back Cover - Driver 2 - Heated Seat Element - Driver Back (KA1) 3 - Seat Back Cushion Pad - Driver 4 - Seat Recline Motor - Driver (1LZ) 5 - Seat Horizontal Motor - Driver (AG1 or 1LZ) 6 - Seat Rear Vertical Motor - Driver (AG1 or 1LZ) 7 - Heated Seat Control Module - Driver (KA1) 8 Seat Front Vertical Motor - Driver (AG1 or 1LZ) 9 - Seat Recline Switch - Driver (1LZ) 10 - Seat Adjuster Switch - Driver 11 - Seat Belt Switch - Driver 12 - Seat Cushion - Driver 13 - Heated Seat Element - Driver Cushion (KA1) 14 - Seat Cover - Driver Passenger Compartment/Roof Component Views Page 2170 Page 4770 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 5956 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 4737 9. Remove the brake caliper guide pins (2) from the brake caliper mounting bracket (4). 10. Remove the caliper pin boots (3) from the brake caliper mounting bracket (4). Installation Procedure 1. Apply a thin coat of high temperature silicone lube to the brake caliper guide pin boots. 2. Install the brake caliper pin boots (3) to the brake caliper mounting bracket (4). 3. Apply a thin coat of high temperature silicone lube to the brake caliper guide pins (2). 4. Install the brake caliper guide pins (2) to the brake caliper mounting bracket (4). 5. Install the brake pad retainers (2) to the brake caliper mounting bracket (3). 6. Install the brake pads (1) to the brake caliper mounting bracket (3). 7. Install the brake caliper to the brake caliper mounting bracket. Page 4269 Page 8216 Page 10072 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Page 7151 1. Install the spring into the J 45400. Make sure the spring is level. 2. Use the J 45400 to compress the spring evenly. 3. Install the lower spring seat insulator. 4. Extend the strut shaft to the upper limit of its travel. 5. Insert the jounce bumper into the dust shield. 6. Slide the dust shield assembly onto the strut shaft. 7. Load the strut through the coil spring and the J 45400. Page 9151 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 10803 3. Position the wiper module assembly (2) into the plenum. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the fasteners (1) attaching the wiper module assembly to the plenum and tighten to 10 Nm (89 lb in). 5. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Air Inlet Grille Panel Replacement). 6. Install the wiper arms. Refer to Windshield Wiper Arm Replacement (See: Wiper Arm/Service and Repair). 7. Inspect the washers for proper operation. Locations Pedal Positioning Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 7648 5. Reposition the heater inlet hose clamp at the engine using the J 38185. 6. Remove the heater inlet hose from the engine. Installation Procedure 1. Install the heater inlet hose to the engine. 2. Reposition the heater inlet hose clamp at the engine using the J 38185. Page 3368 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Locations Steering Control Module: Locations Instrument Panel/Center Console Component Views Instrument Panel Components - Steering Column 1 - Inflatable Restraint Steering Wheel Module Coil 2 - Power Steering Control Module (PSCM) Page 1517 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 9555 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 6298 Fuel Injector 2 (LY7) Fuel Injector 2 (LZ4 or LZE) Locations Ambient Temperature Sensor / Switch HVAC: Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (1 of 2) 1 - Inflatable Restraint Front End Sensor - Left 2 - Ambient Air Temperature Sensor 3 - Inflatable Restraint Front End Sensor - Right Page 7395 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Note: * If the wheels are chrome-plated, do not re-plate or refinish the wheels. * If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: * Corrosion * Scrapes * Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Warning To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: * Lubricants * Wax * Dirt Note: * Do not re-machine the wheel. * Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Note: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Note: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: * Corrosion * Overspray * Dirt 13. Install the tire and wheel assembly to the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Page 2938 Page 3375 the engine at operating temperature. 4. Drive the vehicle until the Fuel Composition Learn parameter displays Inactive. 5. Use the scan tool to reset the fuel trim values. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Fuel System Cleaning (See: Service and Repair) Page 5869 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 3919 Fluid - A/T: Testing and Inspection 6T70/6T75 - Automatic Transmission Transmission Fluid Level and Condition Check This procedure checks both the transmission fluid level, as well as the condition of the fluid itself. Caution: Use Dexron VI transmission fluid only. Failure to use the proper fluid may result in transmission internal damage. Note: Ensure the transmission has enough fluid in it to safely start the vehicle without damaging the transmission. With the vehicle off there must be at least enough fluid to wet the end of the dipstick bullet. This will ensure that there is enough fluid in the sump to fill the components once the vehicle is started. Level Checking Procedure 1. Park the vehicle on a level surface, apply the parking brake and place the shift lever in PARK (P). 2. Start the engine. 3. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in each range. Then move the shift lever back to PARK (P). 4. Allow the engine to idle 500-800 rpm for at least 1 minute. Release the brake pedal. 5. Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver Information Center or a scan tool. Note: If the fluid temperature is below the specified range, perform the following procedure to raise the fluid temperature to the specified range. 6. If the TFT reading is not within the required temperature ranges, allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached. Drive the vehicle in second gear until the fluid temperature is within the specified range. Note: Check the transmission fluid level when the TFT is between 180°F and 200°F (82°C and 93°C). The fluid level rises as fluid temperature increases, so it is important to ensure the transmission fluid temperature is within range. 7. Remove the dipstick and wipe it with a clean rag or paper towel. 8. Inspect the fluid color. The fluid should be red or dark brown. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal particles or other debris. A small amount of "friction" material is a "normal" condition. If large pieces and/or metal particles are noted in the fluid, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs of transmission internal damage noted, replace the fluid, repair the oil cooler, and flush the cooler lines. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission (See: Testing and Inspection/Symptom Related Diagnostic Procedures/6T70/6T75 - Automatic Transmission/Engine Coolant/Water in Transmission). 9. Install the dipstick and tighten. Wait three seconds and then remove it again. Note: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 10. Check both sides of the dipstick and read the lower level. Note: It is not necessary to get the fluid level all the way up to the MAX mark. Anywhere within the crosshatch band is acceptable. 11. Install and remove the dipstick again to verify the reading. 12. If the fluid level is not within the crosshatch band, and the transmission temperature is between 180°F and 200°F (82°C and 93°C), add or drain fluid as necessary to bring the level into the crosshatch band. If the fluid level is low, add only enough fluid to bring the level into the crosshatch band. Note: Do not add more than one pint (0.5L) at a time without rechecking the level. Once the oil is on the dipstick bullet, it will not take much more fluid to raise the fluid level into the crosshatch band. Do not overfill. Also, if the fluid level is low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis (See: Testing and Inspection/Component Tests and General Diagnostics/6T70/6T75 - Automatic Transmission/Fluid Leak Diagnosis). 13. If the fluid level is in the acceptable range, install the dipstick. 14. If the fluid was changed, reset the transmission oil life monitor if applicable. Fluid Condition Inspection * Inspect the fluid color. The fluid should be red in color. The fluid may also turn brown form normal use, and does not always indicate contamination. Page 3008 Body Control Module (BCM) X4 Page 9379 Note: Ensure that the window trade mark is at the rear of the opening. 1. Position the sunroof window into the opening. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the sunroof window screws. Do not tighten the screws. Tighten the bolts to 4 Nm (35 lb in). 3. Carefully close the sunroof window from the vent position to the full closed position. 4. Adjust the sunroof window. Refer to Sunroof Window Height and Opening Fit Adjustment (See: Adjustments). 5. Close the sunshade. 6. Cycle the sunroof window to ensure proper operation and fit. Page 7431 Page 3708 Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 4. Remove the transaxle range switch lever nut and lever. 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. Page 1175 Disclaimer Page 3469 Page 985 1 - Steering Wheel Position Sensor (NVH) TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 9513 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Locations Control Module HVAC: Locations Instrument Panel/Center Console Component Views Under the Right Side of the Instrument Panel Components 1 - Blower Motor 2 - Blower Motor Control Module (C68) 3 - Blower Motor Resistor (C60) Page 5216 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 4341 Note: Install all bolts before tightening, then tighten in specified sequence. 4. Install the 8 control valve body bolts (1) M6 x 65 and tighten to 12 Nm (106 lb in). 5. Install the 2 control valve body bolts (3) M6 x 55 and tighten to 12 Nm (106 lb in). Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 6. Install a NEW control solenoid valve assembly filter plate (1). 7. Install the control solenoid valve body and TCM assembly (5). 8. Rotate the control solenoid valve spring (7) into position. Note: Install all bolts before tightening, then tighten in specified sequence. 9. Install the 4 control valve body bolts (1) M6 x 80. Page 4631 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Electronic Components (MH8) Exploded Views Shift Solenoid: Exploded Views 6T30/6T40/6T45 - Automatic Transmission Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly Page 2673 Camshaft Position (CMP) Sensor - Bank 2 Exhaust (LY7) A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Locations Lateral Accelerometer: Locations Passenger Compartment/Roof Component Views Roof/Headliner and Under the Center Console Components 1 - Inflatable Restraint Roof Rail Module - Right Front 2 - Inflatable Restraint Roof Rail Module Left Front 3 - Yaw and Lateral Accelerometer Sensor 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Page 1062 1 - Window Switch - Left Rear 2 - Window Switch - Right Rear 3 - Door Latch - Right Rear 4 Window Motor - Right Rear 5 - Window Motor - Left Rear 6 - Door Latch - Left Rear Page 10120 * J-38125-8 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Page 5579 Speaker - Left Front (UQA) Page 8354 Disclaimer Page 7452 Side Window Defogger Outlet Duct Replacement - Right Side Removal Procedure 1. Remove the instrument panel (I/P) assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). 2. Remove the right hand side window defogger duct screws. 3. Remove the right hand side window defogger duct. Installation Procedure 1. Install the right hand side window defogger duct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Page 8608 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 1022 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Service and Repair Windshield Washer Switch: Service and Repair Windshield Wiper and Washer Switch Replacement Page 2405 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor (2). 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2). Installation Procedure Page 3941 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. Page 5614 Vehicle Communication Interface Module (VCIM) X2 (UE1) Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 5418 Digital Video Disc (DVD) Display - Driver Seat Headrest X1 (SPO Accessory) (UJ5) Page 2889 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 2065 Caution: Do not coat spark plug threads with anti-seize compound. If anti-seize compound is used and spark plugs are over-torqued, damage to the cylinder head threads may result. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the spark plugs and tighten the plugs to 20 Nm (15 lb ft. The spark plug gap is 1.0 mm (0.040 in). 2. Install the ignition coil(s). Refer to Ignition Coil Replacement (See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair). Page 3107 Camshaft Position (CMP) Sensor - Intake (LAT or LE5 or LE9) Trim Height Specifications Alignment: Specifications Trim Height Specifications Trim Height Specifications Page 1630 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 2717 - Select Fuel Composition Reset (F1). - The first parameter is "Fuel Alcohol Content" displayed as a percentage. If the Fuel Alcohol Content percentage is above 25%, this is the probable cause of DTC P0172. - From this screen the "Fuel Alcohol Content" can be reset to zero by pressing the lower right Tech 2(R) button. It will then display 0% when it's reset. Finally, reprogram the PCM with the latest calibration. This will correct for the PCM alcohol calculations. Note The PCM must be reset from this screen. It does not reset to zero when the PCM is reprogrammed. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6470 Audio Amplifier X2 (UQA) Page 6958 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Page 1857 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Page 6263 Page 3704 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH8) Page 9298 Page 4239 Transmission Mode Indicator - A/T: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Automatic Transmission Control Indicator Replacement Page 7196 Disclaimer Page 1417 Fuse Block - Rear X1 Page 7978 "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN(s) 19118426 and 20968489 will not be eligible for RIM management. * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Service Procedure Replace Wire Harness Connector 2010 Chevrolet Malibu and 2010 Pontiac G6 Tools Required - J 38125-7 Crimp Tool - J 38125-6 Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Seat shown out-of-vehicle for illustration purposed Page 9446 Seat Cover: Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Locations Transmission Mode Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (MH2) 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 4077 Transmission Mode Switch: Service and Repair Manual Shift Auxiliary Position Switch Replacement - Steering Wheel Page 6523 X316 Inline Harness Connector End Views X316 DVD Signal Cable 3B to DVD Signal Cable 1B (SPO Accessory) (UJ5) X309 Inline Harness Connector End Views X309 Body Harness to Right Seat Inflatable Restraint Impact Module Jumper Harness and Pretensioner Page 9646 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Page 9324 3. Remove the rivets from the sunroof cable drive tube retainers which secure the drive tube to the sunroof window track assembly. The 2 rivets are situated on each side. 4. Pull the cable drive tube straight out from the track assembly, allowing the cables to release freely from the tubes. Installation Procedure 1. Position the sunroof drive cables into the openings of the metal tubes on each side of the sunroof cable drive tube. Page 6522 X315 Inline Harness Connector End Views X315 DVD Signal Cable 3A to DVD Signal Cable 1A (SPO Accessory) (UJ5) Page 606 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 1543 Frequently Asked Questions Disclaimer Page 6903 6. Remove the power steering fluid reservoir outlet hose from the vehicle. Installation Procedure 1. Position the power steering fluid reservoir outlet hose to the vehicle. 2. Compress the power steering fluid reservoir outlet hose clamp (1) and connect the power steering fluid reservoir outlet hose (2) to the power steering pump (3). 3. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 4. Compress the power steering fluid reservoir outlet hose clamp (1) and connect the power steering fluid reservoir outlet hose (2) to the remote power steering fluid reservoir (3). 5. Clean any excess power steering fluid from the vehicle and remove the drain pans. 6. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). Page 9141 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Page 2851 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Connector Position Assurance Locks Connector Position Assurance Locks Locations Pressure Regulating Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 8227 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Page 1911 13. LAT only: 1. Disconnect the engine wiring harness electrical connector (1) from the generator control module coolant pump (2). 2. Remove the generator control module coolant pump bolt (3). 3. Remove the generator control module coolant pump from the oil pan. 14. Remove the 4 oil pan to transaxle bolts. 15. Remove the oil pan bolts. Service and Repair Fuel Filler Hose: Service and Repair Fuel Tank Filler Pipe Replacement Removal Procedure Note: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order the avoid possible system contamination. 1. Remove the fuel fill cap. 2. Drain the fuel tank. Refer to Fuel Tank Draining (See: Service and Repair/Procedures). 3. Remove the right rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 4. Remove the fuel tank fill pipe screws (1) from the fuel tank fill pipe housing. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 6. Remove the fuel tank fill pipe bolt (2) from the underbody side rail. Page 6775 Ensure that the appropriate wire colors match up (as noted in Step 4) when the connection is made between the seat airbag harness and body harness. 10. Slide all four terminals (2) into the appropriate connector body as shown above. Install the blue terminal position assurance (TPA) devices onto the connector ends. 11. Add NyoGel 760 Lubricant (dielectric lubricant), P/N 12377900 (in Canada, use P/N 10953529) (Saturn retailers, use P/N 12345579) to the terminals on both sides of the connections. 12. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the body harness up to the back of the connector. 13. Reinstall the conduit on the seat airbag harness. 14. Repeat the above procedure on the passenger seat. Reinstall Seats 1. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 2. Reconnect the seat to body harness connector and the seat airbag connector. Reroute Harness and Secure Connector Follow the procedure below to re-route and attach the harness connector to the body harness bundle: 1. The original seat airbag connector was attached with a clip to the bottom of the seat (2) as shown above. 2. Using two wire ties, secure the seat airbag connector to the seat wire bundle as shown. Ensure that there is enough slack for full range of motion of the seat. 3. Inspect the wires through the full range of motion of the seat again as in Step 2. Ensure that the wires have been secured in an orientation that allows full seat motion with adequate clearance to the connectors and sufficient slack in the wires. 4. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 5. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. 6T30/6T40/6T45 - Automatic Transmission Transmission Speed Sensor: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Output Speed Sensor Replacement Output Speed Sensor Replacement Input Speed Sensor Replacement Input Speed Sensor Replacement Removal Procedure 1. Remove the transmission control valve body cover. Page 7113 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Page 6806 Alignment: Description and Operation Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Page 5749 Fuse Block - Underhood X3 Page 2954 5. Connect the fuel injector wiring harness electrical connector (1) to the MAP sensor. 6. Position the EVAP canister purge tube (1) out of the way. 7. Connect the EVAP canister purge tube to the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 8. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 9702 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 5758 Page 6998 Steering Gear: Locations Power Steering Gear Disassembled View 1 - Steering Gear 2 - Steering Gear Cylinder Pipe 3 - Steering Gear Cylinder Pipe Seal 4 - Steering Gear Cylinder Pipe 5 - Power Steering Gear Inlet Hose Bracket Bolt 6 - Power Steering Gear Inlet Hose Bracket 7 - Rack And Pinion Outer Tie Rod End Nut 8 - Steering Gear Shock Dampener 9 Steering Gear Inner Tie Rod 10 - Inner Steering Gear Boot Clamp 11 - Steering Gear Boot 12 Outer Steering Gear Boot Clamp 13 - Steering Gear Inner Tie Rod Nut 14 - Rack And Pinion Outer Tie Rod End 15 - Steering Gear Boot Breather Tube Page 2300 Body Control Module (BCM) X3 Page 9045 Windshield Pillar Garnish Molding Replacement Windshield Pillar Garnish Molding Replacement Page 6374 Side Marker Lamp - Left Rear Side Marker Lamp - Right Front Side Marker Lamp - Right Rear Page 334 Engine Control Module (ECM) X1 (LZ4 or LZE) Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Page 283 Page 1231 7. Install the radiator surge tank pipe to the crossover pipe. 8. Install the radiator surge tank pipe bolts (2) and tighten to 10 Nm (89 lb in). 9. Install the radiator surge tank inlet hose to the inlet pipe. 10. Position the radiator surge tank inlet hose clamp (1) at the surge tank inlet pipe. 11. Install the power steering pump. Refer to Power Steering Pump Replacement (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering Pump Replacement). 12. Install the drive belt idler pulleys. Refer to Drive Belt Idler Pulley Replacement (). 13. Install the generator. Refer to Generator Replacement (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). 14. Install the intake manifold cover. Refer to Fuel Injector Sight Shield Replacement (). Page 9659 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 6469 Audio Amplifier X1 (UQ3) Page 4224 Page 3962 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (ME7 or MN5) OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 10046 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Page 7929 Disclaimer Service Procedure Service Procedure Air Bag Connector Inspection 1. Move the driver's seat to the maximum forward position and raise the seat to its maximum height. 2. Using a flash light, locate the air bag and body wire harnesses. Note Vehicles that have new air bag connectors will have a tie strap securing the two (2) wires exiting the air bag connector to the main body wiring harness. In addition, the new air bag connectors will have an orange connector position assurance (CPA) clip that is tethered to the connector. Ensure both the orange CPA clip and tie strap are located. Air bag and body wire harnesses without the tie strap and/or CPA clip must have the air bag connectors replaced. 3. Determine if the new air bag connectors have been installed. - If the vehicle is equipped with the new air bag connectors, no further action is required. Refer to Warranty Transaction Information in this bulletin. - If the vehicle is NOT equipped with the new air bag connectors, replace the air bag connectors. Refer to Replace Wire Harness Connector in this bulletin. Replace Wire Harness Connector Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. (Seat shown out-of-vehicles for illustration purposes) Page 4057 Page 3836 2. Attach the ball-sockets to the control assembly body and the shift-lock control lever. 3. Connect the electrical connector to the Shift Lock Control Solenoid. 4. Install the automatic transaxle control assembly. Page 6529 X413 Inline Harness Connector End Views X413 Fuel Sender Harness to Body Harness Locations Brake Booster Vacuum Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Page 5672 X100 Engine Harness to Transmission Harness (MN5) Locations Pressure Regulating Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 5948 Your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle not only meets, but exceeds government standards for side impact protection. GM recently introduced into production, changes that add to that protection. At no charge, your dealer will make similar changes to your vehicle, which was built before the production change. What We Will Do: To enhance the side impact protection, your GM dealer will update the wiring harness for both front seat side impact airbags. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 10085 Page 9307 Page 3978 Page 6667 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6909 7. Connect the power steering gear inlet hose to the power steering pump. Tighten the fitting to 27 Nm (20 lb ft). 8. Install the power steering hose bracket (1) and bracket nut (2). Tighten the nut to 5 Nm (45 lb in). Page 4307 1. Install the 3 input speed sensor seals (1). 2. Install the input speed sensor (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the input speed sensor bolt (2) M6 x 23 and tighten to 12 Nm (106 lb in). 4. Connect the input speed sensor electrical connector (1). 5. Install the transmission control valve body cover. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See: Testing and Inspection/Programming and Relearning/6T30/6T40/6T45 - Automatic Transmission). Page 2810 Page 7767 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Restraints - Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9122 Page 8244 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Page 5761 Fuse Block - Rear X3 Page 5221 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 2229 Specifications) 8. Install the HO2S using J 39194-B. Tighten the sensor to 42 Nm (31 lb ft). 9. Connect the engine wiring harness electrical connector (4) to the HO2S electrical connector (3). 10. Install the HO2S electrical connector rosebud clip to the oil level indicator tube tab. 11. Install the CPA retainer (5). 12. Install the air intake duct. Refer to Air Cleaner Inlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Inlet Duct Replacement). Page 1042 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual Valve Disassembled Views Disassembled Views Case and Associated Parts Page 3624 Shift Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH2) Page 7406 1. Install the wheel bearing/hub assembly to the knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 wheel bearing/hub assembly nuts. Tighten the nuts to 63 Nm (47 lb ft). 3. Install the stabilizer link bolt at the knuckle. Refer to Stabilizer Shaft Replacement (See: Suspension/Stabilizer Bar/Service and Repair/Rear Suspension). 4. Connect the electrical connector to the wheel speed sensor. 5. Install the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 7. Lower the vehicle. Page 3972 Page 3286 Canister Purge Solenoid: Service and Repair Evaporative Emission Canister Purge Solenoid Valve Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Remove the generator battery control module cover, if necessary. 3. Disconnect the engine wiring harness electrical connector (1) from the evaporative emission (EVAP) canister purge solenoid valve (2). 4. Disconnect the chassis EVAP line quick connect fitting (2) from the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Page 3071 Page 2501 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 2 Heated Oxygen Sensor Replacement - Sensor 2 Page 1964 8. Install the camshaft roller followers. 9. Install the camshaft. Refer to Intake Camshaft and Valve Lifter Replacement (See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Intake Camshaft and Valve Lifter Replacement) or Exhaust Camshaft and Valve Lifter Replacement (See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Exhaust Camshaft and Valve Lifter Replacement). 10. If used, remove the EN-43653 - holding tool. 11. If removed, install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). Page 4681 10. Connect the rear brake pipe fitting (1) and tighten to 20 Nm (15 lb ft). 11. Connect the left rear brake pipe fitting (1) and tighten to 20 Nm (15 lb ft). Page 4480 Transmission Mode Switch: Service and Repair Manual Shift Auxiliary Position Switch Replacement - Steering Wheel Locations Steering Angle Sensor: Locations Steering Column Disassembled View 1 - Intermediate Steering Shaft 2 - Intermediate Steering Shaft Bolt 3 - Steering Wheel Position Sensor 4 - Steering Column 5 - Tilt Lever Spring 6 - Tilt Lever Nut 7 - Tilt Lever Bearing 8 - Tilt Lever Spacer 9 - Tilt Lever Retainer 10 - Tilt Lever Retainer 11 - Tilt Lever Cam 12 - Tilt Lever Follower 13 - Tilt Lever 14 - Tilt Lever Spring 15 - Intermediate Steering Shaft Nut Instrument Panel/Center Console Component Views Behind Left Side of the Instrument Panel Components Page 2723 - Select Fuel Composition Reset (F1). - The first parameter is "Fuel Alcohol Content" displayed as a percentage. If the Fuel Alcohol Content percentage is above 25%, this is the probable cause of DTC P0172. - From this screen the "Fuel Alcohol Content" can be reset to zero by pressing the lower right Tech 2(R) button. It will then display 0% when it's reset. Finally, reprogram the PCM with the latest calibration. This will correct for the PCM alcohol calculations. Note The PCM must be reset from this screen. It does not reset to zero when the PCM is reprogrammed. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1233 8. Remove the coolant air bleed hose/pipe from the engine. Installation Procedure 1. Install the coolant air bleed hose/pipe to the engine. 2. Install the coolant air bleed hose to the water outlet. 3. Position the coolant air bleed hose clamp (2) at the water outlet. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the coolant air bleed hose/pipe bolt (3) to the upper intake manifold and tighten to 10 Nm (89 lb in). 5. Position the fuel feed line and install the fuel feed line clip to the stud. 6. Install the fuel feed pipe line nut (2) and tighten to 10 Nm (89 lb in). 7. Install the surge tank inlet hose. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement (See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Radiator Surge Tank Inlet Hose/Pipe Replacement). 8. Install the intake manifold cover. Refer to Fuel Injector Sight Shield Replacement (). Page 4973 Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Vacuum Sensor Replacement Page 3091 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor (2). 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2). Installation Procedure Page 3386 Fuel Injector 2 (LAT or LE5 or LE9) Fuel Injector 2 (LY7) Page 3611 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. Refer to Control Valve Body Cover Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/4T45-E - Automatic Transmission/Control Valve Body Cover Replacement) 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Refer to Control Valve Body Cover Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/4T45-E - Automatic Transmission/Control Valve Body Cover Replacement). Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Description and Operation/4T45-E - Automatic Transmission/Transmission Adaptive Functions). Page 7020 Steering Mounted Controls Transmitter: Diagrams Component Connector End Views Steering Wheel Control Switch - Left (UK3) Steering Wheel Control Switch - Right (UK3) Locations Power Seat Switch: Locations Passenger Compartment/Roof Component Views Seat Components - Driver 1 - Seat Back Cover - Driver 2 - Heated Seat Element - Driver Back (KA1) 3 - Seat Back Cushion Pad - Driver 4 - Seat Recline Motor - Driver (1LZ) 5 - Seat Horizontal Motor - Driver (AG1 or 1LZ) 6 - Seat Rear Vertical Motor - Driver (AG1 or 1LZ) 7 - Heated Seat Control Module - Driver (KA1) 8 Seat Front Vertical Motor - Driver (AG1 or 1LZ) 9 - Seat Recline Switch - Driver (1LZ) 10 - Seat Adjuster Switch - Driver 11 - Seat Belt Switch - Driver 12 - Seat Cushion - Driver 13 - Heated Seat Element - Driver Cushion (KA1) 14 - Seat Cover - Driver Seat Components - Passenger Page 6033 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Bosch Connectors Bosch Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 608 Traction Control Switch: Service and Repair Electronic Traction Control Switch Replacement Page 5467 Fog Lamp Switch (T96) Fuel Injector 1 (LAT or LE5 or LE9) Fuel Injector 1 (LY7) Page 9663 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Page 5421 Digital Video Disc (DVD) Display - Passenger Seat Headrest X2 (SPO Accessory) (UJ5) Radiator Outlet Pipe Replacement Coolant Outlet: Service and Repair Radiator Outlet Pipe Replacement Radiator Outlet Pipe Replacement Front Bumper Impact Bar Bracket Replacement Front Bumper Bracket: Service and Repair Front Bumper Impact Bar Bracket Replacement Front Bumper Impact Bar Bracket Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning (See: Service Precautions/Technician Safety Information/Approved Equipment for Collision Repair Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Remove all related panels and components. 4. Repair as much of the damage as possible. Refer to Dimensions - Body (). 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (). Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Front and Right Side of the Engine Components (LY7) Service Precautions Lifter / Lash Adjuster: Service Precautions Valve Lifter Priming Caution Caution: Ensure each valve lifter is filled with clean engine oil and the valve lifter does not tip over (plunger down) before the installation of the valve lifters. The loss of oil in the valve lifter lower pressure chamber or the dry stroking/cycling of the valve lifter plunger will allow air to travel into the high pressure chamber of the valve lifter. Air in the high pressure chamber of the valve lifter may not be purged causing extensive engine component damage. Page 5450 Engine Control Module (ECM) X2 (LY7) Page 8179 Page 455 Rear Shelf: All Technical Service Bulletins Interior - Rear Shelf Foam Seal Is Loose TECHNICAL Bulletin No.: 09-08-110-001A Date: July 23, 2010 Subject: Loose Foam Seal Between Rear Window Shelf Trim Panel and Rear Glass (Replace Foam Seal) Models: 2008-2011 Chevrolet Malibu Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-110-001 (Section 08 - Body and Accessories). Condition Some customers may comment that the foam seal material between the rear window shelf trim panel (parcel shelf) and the rear glass is loose and exposed. Cause The foam anti-rattle seal may have been stretched when it was applied to the trim panel. Heat can cause the foam to shrink and the adhesive to fail, allowing the seal to separate from the trim panel. Correction Important DO NOT replace the rear window shelf trim panel for this condition. Use the following procedure to install a new foam seal. 1. Remove the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel in SI. 2. Remove the foam seal from the trim panel. 3. Clean any adhesive residue from the attaching surface on the trim panel using a general purpose adhesive cleaner. 4. Install a piece of Kent Industries P/N P46495*, 11 mm X 9 mm (3/8 in X 7/16 in) adhesive-backed pressure sensitive sponge rubber weatherstrip material, or the equivalent, on the trim panel in the location of the original foam seal. 5. Clean any adhesive residue from the rear window using a general purpose adhesive cleaner. 6. Reinstall the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel in SI. Page 2219 1. Install a NEW gasket (6) to the catalytic converter. 2. Install the right (rear) catalytic converter (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the right (rear) catalytic converter bolt (5) and nuts (1) at the exhaust manifold and tighten to 45 Nm (33 lb ft). 4. Install the left (front) catalytic converter to right (rear) catalytic converter nuts (3) and tighten to 25 Nm (18 lb ft). Note: A special anti-seize compound is used on the HO2S threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 5. If reinstalling the old HO2S, coat the threads with anti-seize compound. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) 6. Install the lower right HO2S (2) using the J 39194-B. Tighten the sensor to 42 Nm (31 lb ft). Page 287 Body Control Module: Service and Repair Body Control Module Replacement Page 9535 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Page 4121 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid Page 6424 Steering Wheel Position Sensor (NVH) Specifications Brake Pad: Specifications Brake pads wear limit .......................................................................................................................... .................................................... 0.76 mm (0.030 in) Page 9079 Page 978 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Page 3437 7. Remove the brake, fuel, and EVAP pipe clips (1, 2) from the studs on the front of dash. 8. Remove the brake pipes from the clips. 9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 10. Remove the right rear frame bolts (4). 11. Remove the right rear frame reinforcement (3). Page 8634 Steering Mounted Controls Transmitter: Diagrams Component Connector End Views Steering Wheel Control Switch - Left (UK3) Steering Wheel Control Switch - Right (UK3) Page 3206 1. Install the O-ring onto the VSS. 2. Install the output VSS into the transmission case. Caution: Refer to Fastener Caution 3. Install the VSS stud and tighten the stud to 12 Nm (106 lb in). 4. Install the VSS electrical harness retainer to the VSS stud. 5. Connect the VSS electrical connector. 6. Lower the vehicle. Page 4506 1 - Control Valve Body Cover Assembly 2 - Transmission Fluid Level Indicator Assembly 3 - Fluid Level Indicator Tube - Model Dependent 4 - Fluid Level Indicator Tube Seal - Model Dependent 5 Control Valve Body Cover Assembly Gasket 6 - Control Valve Body Cover Stud 7 - Control Valve Body Cover Bolt 8 - Control Valve Body Bolt 9 - Control Valve Body Bolt 10 - Control Valve Body Cover Wiring Connector Hole Seal 11 - Control Solenoid Valve Spring 12 - Control Valve Body Bolt 13 - Control Valve Body Bolt 14 - Control Valve Body Bolt 15 - Control Solenoid (w/Body and TCM) Valve Assembly 16 - Control Solenoid (w/Body and TCM) Filter Plate Assembly 17 - Manual Shaft Detent Assembly 18 - Control Valve Body Assembly 19 - A/Trans Output Speed Sensor Assembly 20 - A/Trans Output Speed Sensor Bolt 21 - A/Trans Case Assembly 22 - Torque Converter Housing Outer Seal 23 - Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly 24 Front Differential Drive Pinion Gear Lube Tube Page 2660 Body Control Module (BCM) X2 Page 10084 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 7535 4. Remove both upper radiator support bracket bolts. 5. Remove both upper radiator support brackets. 6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 7. Remove the lower radiator air deflector retainers. 8. Remove the lower radiator air deflector. Page 1181 Capacity Specifications Coolant: Capacity Specifications Cooling System ................................................................................................................................... .................................................. 7.5 quarts (7.1 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 1895 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Support Replacement Axle Beam: Service and Repair Support Replacement Support Replacement Special Tools J 45059 Angle Meter Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the rear muffler assembly from the vehicle. Refer to Exhaust Muffler Replacement (See: Engine, Cooling and Exhaust/Exhaust System/Muffler/Service and Repair). Note: If lowering the support to service other rear suspension components, perform steps 4, 5, 7, 9, 10, 11, and 12. 4. Remove the park brake cable retaining bolt (3), park brake cable (1), from the trailing arm assemblies (2). 5. Disconnect the wheel speed sensor electrical connector at the right rear trailing arm mounting bracket. 6. Remove the wheel speed sensor wiring harness from the trailing arm bracket at the right rear of the vehicle. 7. Remove the toe links from the from the vehicle. Refer to Rear Suspension Link Replacement - Toe Link (See: Rear Knuckle Alignment Link/Service and Repair). 8. Remove the lower control arms from the vehicle. Refer to Rear Axle Lower Control Arm Replacement (See: Control Arm/Service and Repair/Rear Suspension/Rear Axle Lower Control Arm Replacement). 9. Remove the rear knuckles from the vehicle. Refer to Knuckle Replacement (See: Rear Knuckle/Service and Repair/Rear Suspension). 10. Secure the rear support to a transmission jack stand. Page 4279 Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 8. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. Page 5947 Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information 1. Submit a transaction using the table below. * The amount identified in the Net Item column should represent the actual cost of the woven polyester electrical tape, required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a customer satisfaction program that affects your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle. Page 10451 Page 3298 6. Support the fuel tank with a suitable adjustable jackstand. 7. Loosen, DO NOT REMOVE the left side fuel tank strap (2) bolts. 8. Loosen, DO NOT REMOVE the right side front fuel tank strap (1) bolt. 9. Remove the right side rear fuel tank strap bolt. 10. Using the adjustable jack, lower the right side of the fuel tank enough to access the EVAP canister vent solenoid valve. 11. Disconnect the fuel tank fuel pump wiring harness electrical connector (1) from the EVAP canister vent solenoid valve. Page 6587 Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation Door Ajar Indicator Description and Operation The instrument panel cluster (IPC) and the driver information display (DID) in the radio illuminate the door ajar indicator when the body control module (BCM) detects that any of the four doors is open. The IPC and DID receive a low speed GMLAN serial data message from the BCM requesting illumination. If the vehicle is shifted out of park with a door open, the BCM sends a low speed GMLAN serial data message to the IPC in order to activate an audible warning. Page 4220 Torque Converter Clutch Solenoid: Diagrams Component Connector End Views Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve (ME7 or MN5) Page 4306 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt (2) M6 x 23. 4. Remove the input speed sensor (3). 5. Remove the 3 input speed sensor seals (1). Installation Procedure Tires/Wheels - Tire Puncture Repair Procedures Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Page 8173 Page 2433 Page 9203 Page 9448 Dye Transfer: Dye transfer will happen any time a natural fiber like cotton, silk, wool, or suede comes into contact with leather. The lighter the leather color, the more quickly the dye transfer will appear. Leather should be cleaned on a regular basis so that the dirt and grime do not adversely affect the top coat of the leather. After cleaning the leather, it is important to treat the surface with the restorer. Extractor Machine and Concentrate For difficult to clean materials or when cleaning a large area, the best results will be achieved when using an extractor machine and concentrate. General Motors offers the Ruby Extractor (P/N 627-CC-3000AU) through GM Tools and Equipment 1-800-GM-TOOLS, and has recently released a concentrate for use with the extractor machine. Whichever extractor machine is used, it should meet the minimum specifications of the Ruby Extractor: Ruby Extractor Specifications: - Pump PSI: 55 - Water Lift: 85" - Hose Length: 10 ft Important The Ruby Extractor also comes with a 6 year Outer Body and 3 year Parts warranty. Extractor: The Ruby Extractor machine was designed for automotive use and works effectively in the vehicle's interior. The narrow design of the vacuum head allows detail work in tight areas. The water pressure pump is reduced so the fabric surface is not wet more than is necessary. The dry time is greatly reduced due to less water on the fabric surface, the vacuum head making better contact with the surface and the significant water lift capability of the machine. Concentrate: The concentrated extraction cleaner is engineered with lower pH levels to help remove alkaline buildup on fabrics. The concentrate should be mixed according to the instructions listed on the container. The available concentrate helps to break the stain down and then the stain is easily removed with less water. The concentrate used in the Ruby Extractor is slightly acidic to remove soap and alkalinity from the fabric surfaces left behind by using improper, soapy solutions. Dirt, grease and grime are more easily removed when the proper solution is used during the extraction process. Parts Information Products are available in two sizes; 8 oz / 235 ML and 24 oz / 710 ML bottles. Available Equipment Equipment is available by contacting 1-800-GMTOOLS. Page 9161 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. 6T30/6T40/6T45 - Automatic Transmission Shift Solenoid: Specifications 6T30/6T40/6T45 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Page 210 Page 4010 Parking Pawl: Service and Repair 6T70/6T75 - Automatic Transmission Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Page 1049 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt (2) M6 x 23. 4. Remove the input speed sensor (3). 5. Remove the 3 input speed sensor seals (1). Installation Procedure Page 7480 Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor Page 3003 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Page 2354 Page 9944 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 10327 Page 5500 Heated Seat Switch - Driver (KA1) Page 2243 Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor Replacement - Sensor 2). Page 4265 Transmission Mount: Service and Repair 6T70/6T75 - Automatic Transmission Transmission Mount Bracket Replacement - Rear Transmission Mount Bracket Replacement - Rear Transmission Brace Replacement Transmission Brace Replacement Page 6585 Fuse Block - Rear Bottom View TPMS System - Service And Re-Learning Sensor IDs Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 826 Knock Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Lower Front and Rear of the Engine Components (LY7) Page 2860 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Page 10331 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 5954 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Service and Repair Trunk / Liftgate Striker: Service and Repair Rear Compartment Lid Latch Striker Replacement Page 5123 Page 208 Page 10745 1. Position the level indicator seal (3) to the washer solvent container (1), pressing in until fully seated. 2. Using full strength windshield washer solvent on the seal, position the washer solvent level indicator (4) to the washer solvent container (1), pressing in until fully seated. 3. Connect the washer solvent level indicator electrical connector. 4. Install the front wheelhouse panel splash shield. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 5. Fill the washer solvent container with windshield washer solvent. Page 4706 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Page 2137 Heater Hose: Service and Repair Heater Outlet Hose Replacement Heater Outlet Hose Replacement Special Tools J 38185 Hose Clamp Pliers Warning With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. Removal Procedure 1. Partially drain the coolant. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). 2. Remove the surge tank from the surge tank bracket. 3. Reposition the heater outlet hose clamp at the heater core using the J 38185. 4. Remove the heater outlet hose from the heater core. 6T30/6T40/6T45 - Automatic Transmission Shift Solenoid: Specifications 6T30/6T40/6T45 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Page 2347 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 3053 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 3517 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (7) to the intake CMP sensor (6). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 5210 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Diagrams Sun Shade: Diagrams Component Connector End Views Sunshade - Left (LTZ) Sunshade - Right (LTZ) Page 9435 1. Remove the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Seat Cushion/Service and Repair/Rear Seat Cushion Replacement). 2. Remove the rear seat belt buckle nuts (2,3). 3. Remove the outer rear seat belt lower anchors bolts (1,4). 4. Remove the forward seat frame bolt caps and bolts from the rear seat frame. 5. Reposition the seat belts as needed. 6. Fold the rear seat backs to the floor. Page 4884 6. Remove the rear brake hose banjo bolt from the brake caliper. 7. Remove the brake hose from the brake caliper. 8. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end. 9. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. Installation Procedure Note: Install the NEW copper brake hose gaskets. 1. Remove the caps or plugs from the opening in the brake caliper and the brake hose. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install 2 new copper gaskets, the brake hose and the brake hose-to-caliper bolt to the brake caliper and tighten the bolt to 50 Nm (37 lb ft). Page 6602 Fuse Block - Underhood Top View (LE5 or LE9) Page 9171 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Page 9172 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 3270 12. Remove the lower right and left HO2S (1, 2) using the J 39194-B. 13. Remove the left (front) catalytic converter to right (rear) catalytic converter nuts (3). 14. Remove the right (rear) catalytic converter bolt (5) and nuts (1) at the exhaust manifold. 15. Remove and discard the gasket (6). 16. Remove the right (rear) catalytic converter (2). 17. Remove the left (front) catalytic converter (4). 18. Remove and discard the left (front) catalytic converter to manifold gasket. 19. Inspect the catalytic converter-to-exhaust manifold flange. * Service Limit: 0.7 mm (0.028 in) max. * Standard: 0.7 mm (0.028 in) max. Installation Procedure Page 1017 Transmission Mode Switch: Service and Repair Manual Shift Auxiliary Position Switch Replacement - Steering Wheel Page 5347 Power Steering Fluid Reservoir Inlet Hose Replacement Power Steering Line/Hose: Service and Repair Power Steering Fluid Reservoir Inlet Hose Replacement Power Steering Fluid Reservoir Inlet Hose Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). 2. Remove as much power steering fluid from the power steering fluid reservoir as possible. 3. Place drain pans under the vehicle as needed. 4. Compress the power steering reservoir inlet hose clamp (1) and disconnect the power steering reservoir inlet hose from the power steering fluid reservoir. 5. Remove the power steering hose bracket and nut (1, 2). Page 4375 8. Place approximately half of the grease from the service kit in the halfshaft inboard seal. Use the remainder of the grease to repack the housing. Note: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1). 9. Install the trilobal tripot bushing (3) to housing (1). 10. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal. 11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar. 12. Slide the large diameter of the halfshaft inboard seal (2), with larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove. 13. Position the joint assembly at the proper vehicle dimension, a = 106 mm (4.00 in). 14. Carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the trilobal tripot bushing in order to equalize the pressure. Remove the tool. Page 7541 10. The radiator air side seals must be in the proper position for proper airflow. 11. Install both lower radiator mounting brackets. 12. Install both lower radiator mounting brackets bolts and tighten to 60 Nm (44 lb ft). 13. Install the liquid line to the condenser. 14. Install the compressor hose to the condenser. Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat OnStar(R) - Availability for Hearing Impaired Navigation System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 3404 5. Pull the connection apart. Caution: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 6. Use a clean shop towel in order to wipe off the male pipe end. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. Installation Procedure Warning In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male pipe end. 2. Push both sides of the fitting together in order to snap the retaining tabs into place. 3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure. 4T45-E - Automatic Transmission Shift Solenoid: Service and Repair 4T45-E - Automatic Transmission 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions See: Description and Operation. 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of Page 5549 Outside Rearview Mirror - Driver (DD0) Outside Rearview Mirror - Driver (D49 or DP2) Page 2764 Page 10669 Rear Door Window Glass: Service and Repair Rear Side Door Stationary Window Replacement Rear Side Door Stationary Window Replacement 4T45-E - Automatic Transmission Transmission Mode Indicator - A/T: Service and Repair 4T45-E - Automatic Transmission Automatic Transmission Control Indicator Replacement Page 5751 Fuse Block - Underhood X4 Page 9130 Keyless Entry Transmitter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 10727 10. Use the appropriate tool, carefully cut the lace (1) by starting in the center and working down both sides of the window, if equipped. 11. Remove the window from the auto-adhesive as follows: * Leave a base of urethane approximately 2 mm (0.078 in) on the pinch-weld flange. * The only suitable lubrication is clear water. * Use S-0201964 - Bonded, Glass Removing Device. Note: Use care when removing the window not to cut off the locator pins in the left and right upper corners. If the locating pins are cut off it will be necessary to use masking tape to tape the window in place until the auto-adhesive cures. 12. Start the cut between the center of the windshield and the "A" pillar. 1. Do this from inside the vehicle, insert the tool S-0201964 - Bonded, Glass Removing Device (1) between the "A" pillar and the windshield, thus perforating the adhesive. 2. Move the cutting wire along the outside edge of the window. 3. Remove the tool S-0201964 Bonded, Glass Removing Device. 4. Do this from inside the vehicle, install the cutting wire special tool S-0201964 - Bonded, Glass Removing Device (1). 5. Do this from outside the vehicle, install the cutting wire special tool S-0201964 - Bonded, Glass Removing Device (2). 6. With an assistant, use the special tool S-0201964 - Bonded, Glass Removing Device (1) to hold the cutting wire, pull it starting from the outside, back and forth releasing the window from the adhesive. 7. While cutting the window reposition the cutting wire and special tools, so as to cut the adhesive along the window completely. 13. Remove the window from the vehicle with an assistant, use the glass handling suction cups. Installation Procedure 1. If reusing or replacing the window, use the appropriate tool, remove the auto-adhesive bead on the window surface and pinch-weld flange to approximately 2 mm (0.078 in). 2. Clean the bonding area of the window. Page 5942 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. 2008 Model Year Buick Enclave, GMC Acadia and Saturn OUTLOOK Vehicles Only Note The seat mounted side impact airbag connection to the body harness is located at the forward edge of the seat, below the plastic trim. The connectors are yellow. The body harness wires are exposed - running forward in the vehicle, down through the carpet cutout in the floor. Page 482 Page 1423 Fuse Block - Rear X4 Page 5858 Your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle not only meets, but exceeds government standards for side impact protection. GM recently introduced into production, changes that add to that protection. At no charge, your dealer will make similar changes to your vehicle, which was built before the production change. What We Will Do: To enhance the side impact protection, your GM dealer will update the wiring harness for both front seat side impact airbags. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 10085 Page 9672 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Locations Antenna Control Module: Locations Luggage Compartment/Rear of Vehicle Component Views Rear Window Shelf Components 1 - Cellular (UE1) and Digital Radio Antenna (U2K) 2 - Radio Antenna Module 3 - Remote Start Antenna (AP3) 4 - Speaker - Right Rear 5 - Accessory AC/DC Power Control Module (KV1) 6 Audio Amplifier (UQ3) 7 - Rear Compartment Courtesy Lamp 8 - Remote Control Door Lock Receiver (RCDLR) 9 - Digital Radio Receiver (U2K) 10 - Speaker - Left Rear Page 10630 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Brake Pedal Position Sensor Calibration Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Calibration Brake Pedal Position Sensor Calibration Calibration Criteria Important: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor (BPPS) calibration must be repeated. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or body control module (BCM) have been serviced. The calibration procedure will set the brake pedal position sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via the GMLAN communication bus. Calibration Procedure 1. Apply the parking brake. 2. Place the transmission in the PARK position. 3. Install a scan tool. 4. Clear all BCM DTCs before proceeding. 5. Navigate to the Vehicle Control Systems menu. 6. Select Module Setup menu item. 7. Select BCM menu item. 8. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen. Exploded Views Shift Solenoid: Exploded Views 6T30/6T40/6T45 - Automatic Transmission Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly Page 10261 Ambient Light Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C60) 4T45-E - Automatic Transmission Transmission Mode Indicator - A/T: Service and Repair 4T45-E - Automatic Transmission Automatic Transmission Control Indicator Replacement Page 1834 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the camshaft cover and bolts. Tighten the bolts to 10 Nm (89 lb in). 2. Install the feed line retainers (1, 2) to the engine brackets. Page 5171 Page 1425 Page 6251 Dome/Reading Lamps Page 244 Page 6416 Starter Generator X2 (KY1) Page 6996 7. Wipe off any excessive grease on the intermediate shaft to avoid damage from drips on the carpet. 8. Install the instrument panel insulator panel - left side. 9. Verify that the noise is no longer present. Condition 2 There may be interference between the clamp and the steering gear input shaft. The clamp is beveled and if forced down on the input shaft too hard, it may cause a loose fit with the intermediate shaft to input shaft joint. Correction 2 To correct this condition, perform the following steps: 1. Remove the intermediate shaft pinch bolt at the steering gear end. 2. Install a new bolt, GM P/N 07845238, but do not tighten the bolt at this time. 3. Pry the clamp up using a pry bar to position the bolt into the upper part of the groove as shown above. This will position the clamp off the bevel. 4. While keeping the clamp in the upper position, tighten the bolt. Tighten Tighten the bolt to 49 Nm (36 lb ft). 5. Verify that the clunk noise is no longer present. Condition 3 Important This condition ONLY applies to 2004-2007 Chevrolet Malibu/Maxx and 2005-2007 Pontiac G6. Some customers may comment on a knocking or rattling type noise from the front of the vehicle when driven at low speeds and over bumps. The noise only occurs when the steering wheel is in the straight ahead position and sounds like the noise is in the left suspension of the vehicle or directly in front of the driver. Correction 3 1. Ensure the noise is not caused by Condition # 1. 2. Determine the source of the noise. Install the chassis ears at the following locations: - sway bar link - one side at a time - upper strut mount - one side at a time - steering gear near the pinion area - base of the steering column housing - radiator surge tank 3. If the noise is coming from the upper strut mount or sway bar link, replace as necessary and retest. 4. For 2004-2006 Chevrolet and Pontiac model year vehicles, the noise may be coming from the radiator surge tank area. (The 2007 model year vehicles use a different style radiator surge tank - refer to Step 9.) 5. If the noise is coming from the radiator surge tank, release the two retaining tabs holding the radiator surge tank and reposition the tank away from the attaching bracket and isolate with closed cell foam. 6. Cut three pieces of closed cell foam, P/N P46515 (or equivalent), into 25 mm (1 in) by 102 mm (4 in) pieces. 7. Cut two pieces of closed cell foam into 25 mm (1 in) by 6 mm (1/4 in) pieces. Page 1021 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH8) Page 4379 17. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 18. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. * The inner and outer race assemblies * The CV joint cage * The chrome alloy balls 19. Dry all the parts. 20. Check the CV joint assembly for the following items: * Unusual wear * Cracks * Damage 21. Replace any damaged parts. 22. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Installation Procedure Locations Power Mirror Switch: Locations Door Component Views Driver Door Components 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Page 5644 Audio Amplifier X3 (UQ3) Page 10032 HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic HVAC Control Module Replacement HVAC Control Module Replacement Blower Motor Control Processor Replacement Blower Motor Control Processor Replacement Page 10776 7. Disconnect the washer level indicator electrical connector (1). 8. Disconnect the washer pump electrical connector (2). 9. Remove the washer solvent container nuts (3). 10. Remove the washer solvent container (4) from the left frame rail. 11. Remove and transfer the following components from the washer solvent container: * The windshield washer pump assembly and seal-Refer to Windshield Washer Pump Replacement (See: Windshield Washer Pump/Service and Repair). * The washer level indicator and seal-Refer to Windshield Washer Solvent Level Indicator Replacement (See: Sensors and Switches - Wiper and Washer Systems/Washer Fluid Level Switch/Service and Repair). Installation Procedure 1. Install the following components to the washer solvent container: * The windshield washer pump assembly and seal-Refer to Windshield Washer Pump Replacement (See: Windshield Washer Pump/Service and Repair). * The washer level indicator and seal-Refer to Windshield Washer Solvent Level Indicator Replacement (See: Sensors and Switches - Wiper and Washer Systems/Washer Fluid Level Switch/Service and Repair). 2. Position the washer solvent container (4) to the left frame rail mounting studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the washer solvent container nuts (3) and tighten to 10 Nm (89 lb in). 4. Connect the washer pump electrical connector (2). 5. Connect the washer level indicator electrical connector (1). 6. Connect the washer pump hose to the pump spout. 7. Engage the washer pump hose to the washer container. 8. Install the front wheelhouse panel splash shield. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 9. Lower the vehicle. 10. Install the washer container filler tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement (See: Windshield Washer Solvent Container Filler Tube Replacement). 11. Fill the windshield washer container with clean windshield washer solvent. 12. Inspect the washers for proper operation. 13. Close the hood. Page 8314 Cellular Phone Microphone: Diagrams Component Connector End Views Cellular Telephone Microphone (UE1) Page 6574 Fuse Block - Underhood X1 Page 6619 Page 1541 Customer TPMS Information Page 1038 3 - Torque Converter Assembly 4 - Manual Shaft and Detent Lever Assembly 5 - 2nd Clutch 6 Reverse Clutch 7 - Coast Clutch 8 - Direct Clutch 9 - Reaction Planetary Gear Set 10 - Input Planetary Gear Set 11 - Forward Clutch 12 - Lo Roller Clutch 13 - Parking Lock Actuator Assembly 14 - Differential and Final Drive Assembly 15 - Output Stub Shaft 16 - Output Speed Sensor 17 Lo/Reverse Servo Assembly 18 - Lo/Reverse Band 19 - Oil Feed Tube Assembly 20 - Input Sprag Clutch Assembly 21 - Oil Filter Assembly 22 - 2nd Roller Clutch 23 - Oil Level Control Valve 24 Drive Link Assembly 25 - Driven Sprocket 26 - Output Shaft 27 - Channel Plate Assembly 28 Input Speed Sensor 29 - 4-3 Solenoid 30 - Drive Sprocket 31 - Control Valve Body Assembly 32 Oil Pump Assembly 33 - Auxiliary Pump Disassembled Views Disassembled Views Case and Associated Parts Diagrams Ignition Coil: Diagrams Component Connector End Views Ignition Coil 1 (LAT or LE5 or LE9) Ignition Coil 1 (LY7) Page 9147 6. Release the rear lower half of the wire dress cover. 7. Release the tabs that are holding the wire dress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Diagrams Horn Switch: Diagrams Component Connector End Views Horn Switch Service and Repair Tail Lamp Control Module: Service and Repair Tail Lamp Control Module with Bulb Replacement Page 6162 Fuse Block - Underhood Bottom View Locations Pedal Positioning Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 3686 Page 6460 A/C Compressor Clutch A/C Refrigerant Pressure Sensor Page 10185 Disclaimer Page 4085 Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 4. Remove the transaxle range switch lever nut and lever. 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. Page 9502 Page 9956 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Page 3288 1. Install the EVAP canister purge valve to the bracket. 2. Position the EVAP canister purge valve with bracket to the cylinder head. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the EVAP canister purge valve bracket bolt and tighten to 25 Nm (18 lb ft). 4. Connect the engine EVAP line (1) quick connect fitting to the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Page 5713 X701 Inline Harness Connector End Views X701 Left Rear Door Harness to Left Rear Door Trim Pad Harness Page 6061 Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 9526 The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors) * Delphi Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors) * FCI Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors) * Yazaki Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy Page 4638 1 - Control Valve Body Cover Bolt 2 - Control Valve Body Cover Assembly 3 - Control Valve Body Cover Gasket 4 - Control Valve Body Bolt 5 - Control Valve Body Cover Hole Seal 6 - Control Solenoid Valve Heat Sink Bolt 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Control Valve Body Filter Plate Assembly 9 - Control Valve Body Bolt 10 - Control Valve Body Bolt 11 Control Valve Body Assembly 12 - Control Valve Body Spacer Plate Assembly 13 - A/Trans Fluid Level Control Valve 14 - A/Trans Fluid Level Control Valve Gasket 15 - A/Trans Output Speed Sensor Bolt 16 - A/Trans Output Speed Sensor Assembly 17 - Manual Shaft Detent Spring Bolt 18 - Manual Shaft Detent Lever Spring Assembly 19 - A/Trans Input Speed Sensor Assembly 20 A/Trans Input Speed Sensor Assembly O-Ring Seal 21 - A/Trans Input Speed Sensor Bolt 22 - Fill Cap 23 - Fill Cap Seal 24 - Torque Converter Housing Gasket Wheel Alignment Measurement Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections in order to ensure correct alignment readings: * Inspect for visible damage to the suspension components and replace as necessary. * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label) and Tire Diagnosis - Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear). * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Specifications). * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis). * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Specifications/Mechanical Specifications/Steering/System Specifications). * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle). * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Steering and Suspension/Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Note: * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear toe adjustment first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Page 2509 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH8) Page 2251 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust manifold lower heat shield bolts (1, 2). * Tighten the bolt (1) to 10 Nm (89 lb in). * Tighten the bolt (2) to 50 Nm (37 lb ft). 3. Install the catalytic converter. Refer to Catalytic Converter Replacement - Right Side (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Right Side). Page 8119 Page 2122 lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If reinstalling the original sensor, or if installing a NEW sensor without a sealer, coat the threads with sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor (1) to the thermostat housing and tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). Page 7351 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 6772 Note DO NOT replace the sensing and diagnostic module (SDM), side sensors or air bag modules. Note Both driver and passenger seats must be repaired when this concern occurs even if only one DTC code is set. The service kit contains sufficient components to repair both seat connectors. Connector Replacement Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above includes harness and connector clips, which are not required in this installation. Replace connectors on both driver and passenger seats, and then reposition the connectors following the steps below. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Note Only use hand tools to remove the seat to floor mounting bolts. If there are any problems with bolt removal, refer to Corporate Bulletin Number 10-08-50-002. 2. Remove the driver's seat to floor mounting bolts. Loosen the seat from the front retainers and tilt it back to expose the underside of the seat. Refer to Front Seat Replacement - Bucket in SI. Page 6570 Fuse Block - Underhood Top View (LE5 or LE9) Page 5578 Secondary Air Injection (AIR) Pump Solenoid Bank 1 (LZ4 with NU6, or LZE with NU1 or NU5) Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 974 1. Slide the steering wheel position sensor into place and remove the locating pin. 2. Connect any electrical connectors as needed. 3. Connect the intermediate steering shaft to the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 4. Remove anti-rotation pin J 42640. Page 339 Page 6442 Vehicle Communication Interface Module (VCIM) X1 (UE1) Page 338 Engine Control Module (ECM) X2 (LE5 or LE9) Page 4233 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 6329 Heated Seat Switch - Driver (KA1) Service and Repair Battery Tray: Service and Repair Battery Tray Replacement Removal Procedure 1. Remove the battery. Refer to Battery Replacement (See: Service and Repair/Removal and Replacement). 2. Remove the underhood bussed electrical center (UBEC) cover. 3. Loosen the integral bolt (5) on the positive battery cable lead (4) and remove the lead from the UBEC. 4. Reposition the positive battery cable out of the way. 5. Loosen the integral bolt (4) on the steering column harness package lead and remove the lead from the UBEC. Page 3569 Locations Blower Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (except LAT) Page 2213 1. Install a NEW gasket to the left (front) catalytic converter studs. 2. Install the left (front) catalytic converter (4). 3. Install a NEW gasket (6) to the right (rear) catalytic converter studs. 4. Install the right (rear) catalytic converter (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the right (rear) catalytic converter bolt (5) and nuts (1) at the exhaust manifold and tighten to 45 Nm (33 lb ft). 6. Install the left (front) catalytic converter to right (rear) catalytic converter nuts (3) and tighten to 25 Nm (18 lb ft). Note: A special anti-seize compound is used on the HO2S threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 7. If reinstalling the old HO2S, coat the threads with anti-seize compound. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications) Locations Oil Pressure Sender: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) Page 108 Pedal Positioning Module: Diagrams Component Connector End Views Accessory Power Outlet - I/P Accessory Power Outlet - 110V AC (KV1) Page 215 Power Distribution Module: Diagrams Component Connector End Views Accessory AC/DC Power Control Module X1 (KV1) Accessory AC/DC Power Control Module X2 (KV1) Page 1274 7. Remove the power steering hose bracket nut (2) and bracket (1). 8. Disconnect the power steering gear inlet hose from the power steering pump. 9. Disconnect the power steering gear inlet pipe hose retainers. 10. Remove the steering gear. Refer to Steering Gear Replacement (See: Steering and Suspension/Steering/Steering Gear/Service and Repair/Steering Gear Replacement). Page 5514 Ignition Coil 3 (LAT or LE5 or LE9) Page 4139 25 - Torque Converter and Support and A/Trans Fluid Pump Housing Assembly 26 - Torque Converter and Differential Housing Bolt 27 - Torque Converter Assembly 28 - Dust Cover Push Pin - Model Dependent 29 - Dust Cover Bolt - Model Dependent 30 - Dust Cover - Model Dependent 31 - Front Differential Carrier Assembly 32 - Input Shaft Thrust Bearing Assembly 33 - A/Trans Case Cover Gasket 34 - A/Trans Case Cover Assembly 35 - A/Trans Case Cover Assembly Bolt Page 6152 Body Control Module (BCM) X4 Page 5156 Page 2539 Camshaft Position (CMP) Sensor - Bank 2 Exhaust (LY7) Page 1669 Disclaimer Page 5853 Note DO NOT replace the sensing and diagnostic module (SDM), side sensors or air bag modules. Note Both driver and passenger seats must be repaired when this concern occurs even if only one DTC code is set. The service kit contains sufficient components to repair both seat connectors. Connector Replacement Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above includes harness and connector clips, which are not required in this installation. Replace connectors on both driver and passenger seats, and then reposition the connectors following the steps below. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Note Only use hand tools to remove the seat to floor mounting bolts. If there are any problems with bolt removal, refer to Corporate Bulletin Number 10-08-50-002. 2. Remove the driver's seat to floor mounting bolts. Loosen the seat from the front retainers and tilt it back to expose the underside of the seat. Refer to Front Seat Replacement - Bucket in SI. Page 2111 Page 7698 5. Install the blower motor resistor wire harness connector. 6. Install the blower motor wire harness connector. 7. Install the mode actuator wire harness connector. 8. Install the air temperature actuator wire harness connector. 9. Install the recirculation actuator wire harness connector. 10. Install the I/P assembly. Refer to Instrument Panel Reinforcement Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Reinforcement Replacement). 11. Install the heater hoses to the heater core. Refer to Heater Inlet Hose Replacement (See: Heater Hose/Service and Repair/Heater Inlet Hose Replacement) and Heater Outlet Hose Replacement (See: Heater Hose/Service and Repair/Heater Outlet Hose Replacement). 12. Install the A/C lines to the thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement (See: Expansion Block/Orifice Tube/Service and Repair/Air Conditioning Evaporator Thermal Expansion Valve Replacement). Page 5773 Fuse Block - Underhood Top View (LE5 or LE9) Page 5372 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 3956 Fluid Pan: Service and Repair Oil Pan Replacement Removal Procedure Warning Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. 1. Position the vehicle on a hoist and raise the vehicle. 2. Place a drain pan under the transaxle oil pan. 3. Remove the oil pan bolts from the front and sides only. 4. Loosen the rear oil pan bolts approximately 4 turns. Caution: Pry the oil pan carefully in order to prevent damage to the transaxle case or the oil pan sealing surfaces. 5. Lightly tap the oil pan with a rubber mallet or carefully pry in order to allow the oil to drain. Page 8247 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 7676 Hose/Line HVAC: Service and Repair Suction Screen Replacement Suction Screen Replacement Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Locations Variable Valve Timing Solenoid: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) A/C - Poor Cooling Performance/Condenser Fan Fuse Blown Fuse: All Technical Service Bulletins A/C - Poor Cooling Performance/Condenser Fan Fuse Blown TECHNICAL Bulletin No.: 09-01-38-005 Date: October 09, 2009 Subject: Poor A/C Performance, Cooling Fan Fuse Blown (Install Revised Fuse And Wiring) Models: 2008-2010 Chevrolet Malibu 2006-2010 Pontiac G6 2007-2010 Saturn AURA All with RPO LY7, LZ4, LZ9 or LZE V6 Engine Condition Some customers may comment on poor A/C cooling performance. Technicians may find that the cooling fan fuse is blown. Cause High cooling fan start up loads may cause the 30-amp cooling fan fuse, located in the underhood fuse block, to blow. The lack of air flow through the A/C condenser, caused by the inoperative high-speed cooling fan, may affect the condenser's ability to dissipate heat. Correction Use the following procedure to install a heavier gauge power feed wire from the underhood fuse block to the cooling fan. After the wiring update is completed, replace the 30-amp cooling fan fuse in the underhood fuse block with a 40-amp fuse. 1. Disconnect and remove the battery. Refer to Battery Replacement in SI. 2. Remove the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 3. Disconnect the underhood fuse block from it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. It is only necessary to raise the fuse block enough to access the harness connectors. Do not remove the complete assembly from the vehicle. 4. Locate the engine wiring harness junction block assembly (X1) on the back (underside) of the underhood fuse block and disconnect it from the underhood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 5. Find pin A2, Circuit 532, cooling fan motor supply voltage. Refer to Electrical Center Identification Views, Fuse Block-Underhood X1 in SI. 6. Remove the harness back cover. Remove the TPA (terminal position assurance) clip and remove connector A2 from the junction block. Cut the terminal off and tape the wire end with electrical tape. 7. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 8. Locate the electrical connector to the right cooling fan and disconnect the wiring connector from the fan. 9. Disengage pin B, wire 3 GY, circuit 532, cooling fan motor supply voltage, from the connector housing (pull to seat terminal). Cut the terminal off of the wire and remove the wire from the connector housing. 10. Tape the end of the wire with electrical tape. 11. Prepare a 1.82 m (6 ft) section of automotive grade 5.0 mm (10 GA) wire and an equal length of 6 mm (1/4 in) flexible plastic conduit, GM P/N 12051375. 12. Run the new wire through the fan wire connector housing as shown. 13. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 14. Strip the wire insulation as required and install the terminal, GM P/N 12033997, on the wire. Secure the wire and terminal into the fan wire Page 9638 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Page 10509 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Front and Right Side of the Engine Components (LY7) Front Suspension Wheel Bearing: Service and Repair Front Suspension Front Wheel Bearing and Hub Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 3. Disconnect the wheel speed sensor electrical connector, if equipped. 4. Remove the wheel speed sensor electrical connector from the mounting bracket, if needed. 5. Loosen the wheel drive shaft from the wheel bearing/hub. Refer to Wheel Drive Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement). Page 2929 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 619 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Connector End Views By Name Multiple Junction Connector: Diagrams Connector End Views By Name Ca - Do Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ4 or LZE) Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust (LY7) Page 2062 * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Spark Plug Visual Inspection * Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak coils Locations Transmission Speed Sensor: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH2) Page 9320 2. Do the following from outside the vehicle and through the opening of the sunroof window from the right or left side. 1. Install the guide tab (1) into left front corner. 2. Rotor the sunshade until the guide tab (2) is insert into the right corner. 3. Insert the sunshade guide tab (3) flex the sunshade panel as needed to seat. 4. Arch the sunshade in the rear right corner (4) until guide tab can be installed. 5. Carefully flex the rear of the sunshade under water drain channel to allow the sunshade guide tabs (5) and (6) to clear. 3. While seated inside the vehicle with the sunshade in the closed position, verify that the front of the sunroof is not bent upward. If the sunshade is bent, grab the front middle of the sunshade and carefully pull down to adjust the shade to fit the front center edge. 4. Install the sunroof window panel. Refer to Sunroof Window Replacement (See: Sunroof / Moonroof Panel/Service and Repair). Page 6820 Alignment: Service and Repair Front Caster Adjustment Front Caster Adjustment The front caster is not adjustable. If the front caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Replace any damaged suspension components as necessary. Page 5326 Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 6575 Page 900 Camshaft Position (CMP) Sensor - Bank 2 Exhaust (LY7) Page 9891 Page 6834 Page 970 1 - Steering Wheel Position Sensor (NVH) Page 8524 Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Page 5332 Fuse Block - Underhood Top View (LZ4 or LZE) Page 6332 Ho - In Component Connector End Views Hood Ajar Switch (AP3 or HP7) Page 6396 Seat Adjuster Switch - Passenger (LTZ) Seat Belt Anchor Pretensioner - Driver Page 8359 Digital Video Disc (DVD) Control Module X4 (SPO Accessory) (UJ5) 6T30/6T40/6T45 - Automatic Transmission Transmission Speed Sensor: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Output Speed Sensor Replacement Output Speed Sensor Replacement Input Speed Sensor Replacement Input Speed Sensor Replacement Removal Procedure 1. Remove the transmission control valve body cover. Page 9869 Page 10203 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement Heater Inlet Hose Replacement Special Tools J 38185 Hose Clamp Pliers Warning With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. Removal Procedure 1. Partially drain the coolant. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 2. Remove the surge tank from the surge tank bracket. 3. Reposition the heater inlet hose clamp at the heater core using the J 38185. 4. Remove the heater inlet hose from the heater core. Page 4642 1 - Control Valve Body Cover Assembly 2 - Transmission Fluid Level Indicator Assembly 3 - Fluid Level Indicator Tube - Model Dependent 4 - Fluid Level Indicator Tube Seal - Model Dependent 5 Control Valve Body Cover Assembly Gasket 6 - Control Valve Body Cover Stud 7 - Control Valve Body Cover Bolt 8 - Control Valve Body Bolt 9 - Control Valve Body Bolt 10 - Control Valve Body Cover Wiring Connector Hole Seal 11 - Control Solenoid Valve Spring 12 - Control Valve Body Bolt 13 - Control Valve Body Bolt 14 - Control Valve Body Bolt 15 - Control Solenoid (w/Body and TCM) Valve Assembly 16 - Control Solenoid (w/Body and TCM) Filter Plate Assembly 17 - Manual Shaft Detent Assembly 18 - Control Valve Body Assembly 19 - A/Trans Output Speed Sensor Assembly 20 - A/Trans Output Speed Sensor Bolt 21 - A/Trans Case Assembly 22 - Torque Converter Housing Outer Seal 23 - Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly 24 Front Differential Drive Pinion Gear Lube Tube Page 4731 14. Remove the park brake cable from the caliper. 15. Remove the brake caliper from the brake caliper bracket. Installation Procedure 1. Inspect the caliper slide boots for cuts, tears, or deterioration. If damaged, replace the slides and boots. Refer to Rear Brake Caliper Hardware Replacement (See: Rear Brake Caliper Hardware Replacement). 2. Install the brake caliper to the brake caliper bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 2 brake caliper pin bolts and tighten to 35 Nm (26 lb ft). Service and Repair Fuel Supply Line: Service and Repair Fuel Line Replacement - Chassis Special Tools J 45059 Angle Meter Removal Procedure 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 3. Remove the fuel feed line retainer (1) from the fuel line bracket. 4. Disconnect the fuel feed line quick connect fitting (3) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 5. Disconnect the evaporative emission (EVAP) line quick connect fitting (2) from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 6. Cap the fuel rail pipe and the EVAP purge solenoid in order to prevent possible fuel and/or EVAP system contamination. Page 1767 9. Remove the upper timing chain guide bolts and guide. 10. Remove the timing chain tensioner. Page 5977 Page 5489 Headlamp - Right Low Beam Locations Seat Belt Buckle Switch: Locations Passenger Compartment/Roof Component Views Seat Components - Driver 1 - Seat Back Cover - Driver 2 - Heated Seat Element - Driver Back (KA1) 3 - Seat Back Cushion Pad - Driver 4 - Seat Recline Motor - Driver (1LZ) 5 - Seat Horizontal Motor - Driver (AG1 or 1LZ) 6 - Seat Rear Vertical Motor - Driver (AG1 or 1LZ) 7 - Heated Seat Control Module - Driver (KA1) 8 Seat Front Vertical Motor - Driver (AG1 or 1LZ) 9 - Seat Recline Switch - Driver (1LZ) 10 - Seat Adjuster Switch - Driver 11 - Seat Belt Switch - Driver 12 - Seat Cushion - Driver 13 - Heated Seat Element - Driver Cushion (KA1) 14 - Seat Cover - Driver Seat Components - Passenger Page 9613 Specifications Connecting Rod: Specifications Connecting Rod Bolt First Pass ........................................................................................................... ........................................................................................... 25 Nm (18 lb ft) Final Pass ...................... .............................................................................................................................................................. ........................ 100 degrees Connecting Rod Bore Diameter - Bearing End ....................................................................................................... 52.118-52.134 mm (2.0519-2.05252 in) Connecting Rod Side Clearance ................................................................................................................................... 0.070-0.370 mm (0.0028-0.0146 in) Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Page 5409 Crankshaft Position (CKP) Sensor (LY7) Crankshaft Position (CKP) Sensor (LZ4 or LZE) Page 2840 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. Fuel: Technical Service Bulletins Fuel - GM's Position on Use of E 15 in 2007 Newer M.Y. INFORMATION Bulletin No.: 10-06-04-015 Date: December 08, 2010 Subject: General Motors' Position Regarding Use of E15 in Model Year 2007 and Newer Vehicles Models: 2007-2011 GM Passenger Cars and Trucks General Motors' position regarding the Environmental Protection Agency announcement allowing the use of E 15 in 2007 and newer vehicles: - General Motors' remains focused on securing a safe and positive driving experience for our customers. GM believes that the waiver decision by the EPA regarding E 15 could lead to confusion for consumers as to what fuel their vehicle should use. In response, we will continue to encourage our customers to refer to their vehicle Owner Manual for proper fuel designation. The vehicle Owner Manual specifies that fuels containing more than 10 percent ethanol should not be used in GM vehicles that do not have a flex fuel designation. - GM has the largest fleet of flex fuel vehicles on the road today (over 4 million in the U.S.) and these vehicles can safely use ethanol blends of up to 85 percent ethanol. So blends of E 15 (15 percent ethanol), as in the partial waiver announced, are appropriate for these vehicles. However, ethanol blends greater than E 10 should not be used in GM vehicles that do not have a flex fuel designation as they are not designed and certified to run on gasoline consisting of more than 10 percent ethanol-blend volume to avoid any unintended consequences, as per: their Owner Manual. - We believe biofuels, especially E 85 ethanol, are an effective near-term solution to reduce petroleum dependence and the carbon footprint of driving. As the global leader in producing vehicles designed to handle ethanol blends from E 0 to E 85, GM offers 19 flexible-fuel vehicles for the 2011 model year. Disclaimer Page 6302 Fuel Injector 4 (LZ4 or LZE) Fuel Injector 5 (LY7) Page 5405 Control Solenoid Valve Assembly (MH8) Page 9377 4. Adjust the corners of the window panel (3) using the following guidelines: * Adjust the front of the sunroof window (2) flush to 1 mm (0.04 in) below the top surface of the roof panel. * Adjust the rear of the sunroof window (1) flush to 1 mm (0.04 in) above the top surface of the roof panel. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the sunroof window adjustment screws and tighten to 4 Nm (35 lb in). 6. Inspect the sunroof for proper operation. Page 8295 Keyless Entry Transmitter: Electrical Diagrams Remote Function Schematics Keyless Entry Garage Door Opener Brake Pedal Position Sensor Calibration Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Calibration Brake Pedal Position Sensor Calibration Calibration Criteria Important: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor (BPPS) calibration must be repeated. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or body control module (BCM) have been serviced. The calibration procedure will set the brake pedal position sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via the GMLAN communication bus. Calibration Procedure 1. Apply the parking brake. 2. Place the transmission in the PARK position. 3. Install a scan tool. 4. Clear all BCM DTCs before proceeding. 5. Navigate to the Vehicle Control Systems menu. 6. Select Module Setup menu item. 7. Select BCM menu item. 8. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen. Page 2890 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close Locations Throttle Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left Side of the Instrument Panel Components (1 of 2) 1 - Brake Pedal Position (BPP) Sensor 2 - Accelerator Pedal Position (APP) Sensor 3 - Accelerator Pedal 4 - Brake Pedal Page 5532 Inflatable Restraint Steering Wheel Module Coil X1 Duct Air Temperature Sensor Replacement - Upper Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Upper Duct Air Temperature Sensor Replacement - Upper Glass/Body - Windshield Wiper Performance Windshield: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Page 7417 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the NEW stud into the bearing/hub assembly. Add enough washers (1) in order to draw the stud into the hub. 2. Install and tighten a wheel nut (2) until the head of the wheel stud is fully seated against the back of the bearing hub flange. 3. Remove the wheel nut (2) and the washers (1). 4. Install the brake rotor, and install the brake caliper and bracket as an assembly. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. Page 1395 Locations Transmission Control System Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 6288 Engine Coolant Temperature (ECT) Sensor (LAT or LE5 or LE9) Page 4733 Front Brake Caliper Hardware Replacement Front Brake Caliper Hardware Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 5. Using a C-clamp installed to the center of the outer brake pad and the back of the caliper, slowly compress the caliper piston into its bore just enough to remove the caliper from the mounting bracket. Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 6. To loosen the brake caliper pin bolts, hold the brake caliper guide pin with a wrench. 7. Remove the lower brake caliper pin bolt. 8. Pivot the brake caliper upward and support with mechanics wire as shown. 9. Remove the brake pads (2) from the disc brake caliper bracket. Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 901 Camshaft Position (CMP) Sensor - Bank 2 Intake (LY7) Page 2828 Page 9924 The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors) * Delphi Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors) * FCI Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors) * Yazaki Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy Page 4954 Installation Procedure Important: A small amount of denatured alcohol can be used as an assembly aid when installing the vacuum check valve and/or grommet. Do NOT use soap. 1. If the vacuum hose (2) was removed, install the vacuum hose into position on the vehicle as noted prior to removal, then connect the vacuum hose (2) to the engine intake manifold connection (3) and secure with the vacuum hose clamp (1). 2. If the vacuum check valve (1) is being replaced, install a NEW grommet (4) to the brake booster. 3. If the vacuum check valve (1) was separated from the vacuum hose (3), install the check valve (1) to the vacuum hose (3). Install and secure the clamp (2) into position on the hose (3). 4. Connect the brake booster vacuum check valve (1) to the brake booster. 5. Position the radiator surge tank to the bracket. Refer to Radiator Surge Tank Replacement (See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Radiator Surge Tank Replacement). Page 3789 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid Page 4891 8. Disconnect the left front brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 9. Disconnect the master cylinder primary brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination. Page 5143 Fuel Injector Circuit Diagnosis Fuel Injector: Testing and Inspection Fuel Injector Circuit Diagnosis Fuel Injector Circuit Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The control module enables the appropriate fuel injector pulse for each cylinder. Ignition voltage is supplied to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools J 44603 - Injector Test Lamp Circuit/System Verification Engine idling, observe the following control circuit status parameters for each fuel injector: * Injector Ckt Short Gnd Test Status * Injector Ckt Open Test Status Page 2073 Water Pump: Service and Repair Water Pump Replacement Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (See: Cooling System/Service and Repair/Cooling System Draining and Filling). 2. Loosen the water pump pulley bolts. 3. Remove the drive belt. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 4. Remove the water pump pulley bolts and pulley. 5. Remove the water pump bolts. 6. Remove the water pump and gasket. 7. Clean the water pump mating surfaces. Page 6777 Your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle not only meets, but exceeds government standards for side impact protection. GM recently introduced into production, changes that add to that protection. At no charge, your dealer will make similar changes to your vehicle, which was built before the production change. What We Will Do: To enhance the side impact protection, your GM dealer will update the wiring harness for both front seat side impact airbags. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 10085 Diagrams Garage Door Opener Transmitter: Diagrams Component Connector End Views Garage Door Opener (GDO) (UG1) Page 2541 Camshaft Position (CMP) Sensor - Exhaust (LAT or LE5 or LE9) Page 10566 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 6144 Body Control Module (BCM) Top View Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Front and Right Side of the Engine Components (LY7) Page 6255 Door Lock Switch - Driver Page 9295 Heated Seat Control Module - Passenger X1 (KA1) Page 9643 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Page 5438 Page 5589 Starter Generator Control Module (SGCM) X2 (LAT) Page 4684 1. Install the bracket (1) to the BPMV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the BPMV bolt (1) and tighten to 10 Nm (89 lb in). 3. Install the BPMV. Refer to Brake Pressure Modulator Valve Replacement (See: Brake Pressure Modulator Valve Replacement). Page 5267 3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Page 6662 Disclaimer Page 5885 Disclaimer Page 4705 Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor Page 8670 Page 5420 Digital Video Disc (DVD) Display - Passenger Seat Headrest X1 (SPO Accessory) (UJ5) Page 4054 3. Remove the manual shaft seal (1) using J 45201. Installation Procedure 1. Install the manual shaft and position switch assembly. Refer to Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement ( See: Parking Pawl/Service and Repair/6T30/6T40/6T45 - Automatic Transmission). 2. Install the manual shaft seal (1) using J-46626. 3. Install the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair). Page 618 Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor Page 3899 2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid valve spring (7) into position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Install all bolts before tightening, then tighten in specified sequence. 4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x 55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6 x 42. 8. Install the 2 control valve body bolts (4) M6 x 65 and tighten to 12 Nm (106 lb in). 9. Connect the input speed sensor electrical connector (1). 10. Connect the output speed sensor electrical connector (2). 11. Connect the shift position switch electrical connector (3). 12. Install the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/6T70/6T75 - Page 2903 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 2899 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Page 4337 10. Connect the control valve body TCM electrical connector (1). 11. Install the oil cooler inlet and outlet hoses to the retainer on the control valve body cover. 12. Install the wire harness retainer (2) to the control valve body cover stud. 13. Tighten the nut to 12 Nm (106 lb in). 14. Install the front transmission mount. Refer to Transmission Front Mount Replacement (See: Transmission Mount/Service and Repair/6T70/6T75 - Automatic Transmission/Transmission Front Mount Replacement). 15. Install the front air dam. Refer to Front Air Deflector Replacement (See: Body and Frame/Spoilers, Flaps, and Air Dams/Air Dam/Service and Repair/Front Air Deflector Replacement). 16. Install the left engine splash shield. Refer to Engine Splash Shield Replacement - Left Side (See: Body and Frame/Splash Guard/Service and Repair/Engine Splash Shield Replacement - Left Side). 17. Lower the vehicle. 18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 19. Fill the transmission. Refer to Transmission Fluid Replacement (See: Service and Repair/Removal and Replacement/6T70/6T75 - Automatic Transmission/Transmission Fluid Replacement). 20. Install the air cleaner outlet duct. Page 197 Page 669 Solar Sensor: Diagrams Component Connector End Views Sunload Sensor (C68) Page 4636 64 - Band Anchor Pin (Lo/Reverse) 65 - Oil Level Control Plug 81 - Tube Assembly Bolt/Bottom Pan Bolt 84 - Transaxle Oil Filter Seal 85 - Transaxle Oil Filter Assembly 86 - Oil Level Control Valve 87 - Transaxle Bottom Pan Gasket 88 - Transaxle Oil Pan 89 - Chip Collector Magnet 120 Chip Collector Magnet (Some Models) 126 - Side Cover Stud 130 - A/Trans Auxiliary Fluid Pump Assembly 131 - Auxiliary Trans Fluid Pump Bolts 132 - Auxiliary Pump Pipe Bolts Component Location Component Location Transmission Major Components 1 - TFP Manual Valve Position Switch Assembly 2 - Control Valve Body Assembly Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Rear Side Door Window Replacement Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement Rear Side Door Window Replacement Page 7095 6. Remove the toe link to knuckle bolt. 7. Remove the rear coil spring. Refer to Coil Spring Replacement (See: Suspension Spring ( Coil / Leaf )/Service and Repair/Rear Suspension Coil Spring/Coil Spring Replacement). 8. Remove the stabilizer shaft to knuckle bolt. Page 927 Knock Sensor (KS) 2 (LZ4 or LZE or LY7) Page 7241 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 1567 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 3073 Engine Control Module: Description and Operation Engine Control Module Description The engine control module (ECM) interacts with many emission related components and systems, and monitors the emission related components and systems for deterioration. OBD II diagnostics monitor the system performance and a diagnostic trouble code (DTC) sets if the system performance degrades. The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type. A DTC is ranked as a Type A or Type B if the DTC is emissions related. Type C is a non-emissions related DTC. The ECM is in the engine compartment. The ECM is the control center of the engine controls system. The ECM controls the following components: * The fuel injection system * The ignition system * The emission control systems * The on-board diagnostics * The A/C and fan systems * The throttle actuation control (TAC) system The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect the vehicle performance and the emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the MIL. When the ECM detects a malfunction, the ECM stores a DTC. The condition area is identified by the particular DTC that is set. This aids the technician in making repairs. ECM Function The engine control module (ECM) can supply 5 V or 12 V to the various sensors or switches. This is done through pull-up resistors to the regulated power supplies within the ECM. In some cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is too low. Therefore, a DMM with at least 10 Mohm input impedance is required in order to ensure accurate voltage readings. The ECM controls the output circuits by controlling the ground or the power feed circuit through the transistors or a device called an output driver module. EEPROM The electronically erasable programmable read only memory (EEPROM) is a permanent memory that is physically part of the engine control module (ECM). The EEPROM contains program and calibration information that the ECM needs in order to control the powertrain operation. Special equipment, as well as the correct program and calibration for the vehicle, are required in order to reprogram the ECM. Data Link Connector (DLC) The data link connector (DLC) is a 16-pin connector that provides the technician a means of accessing serial data for aid in the diagnosis. This connector allows the technician to use a scan tool in order to monitor the various serial data parameters, and display the DTC information. The DLC is located inside of the drivers compartment, underneath the dash. Malfunction Indicator Lamp (MIL) The malfunction indicator lamp (MIL) is inside of the instrument panel cluster (IPC). The MIL is controlled by the engine control module (ECM) and illuminates when the ECM detects a condition that affects the vehicle emissions. ECM Service Precautions The engine control module (ECM), by design, can withstand the normal current draws that are associated with the vehicle operations. However, care must be used in order to avoid overloading any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the ECM circuits unless the diagnostic procedure instructs you to do so. These circuits should only be tested with a DMM. Emissions Diagnosis For State I/M Programs This OBD II equipped vehicle is designed to diagnose any conditions that could lead to excessive levels of the following emissions: * Hydrocarbons (HC) * Carbon monoxide (CO) * Oxides of nitrogen (NOx) Page 6076 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 10640 For vehicles repaired under warranty, use the table. Disclaimer Page 1945 5. Position the starter/generator to the bracket. 6. Install the starter/generator bolts until snug. 7. Tighten the starter generator bolts in the following sequence: 1. Front 2. Bottom Tighten the bolts to 58 Nm (43 lb ft). 8. Install the 3-phase voltage cable bracket to the tie bar. 9. Install the 3-phase voltage cable bracket bolt (1) at the oil level indicator tube. Tighten the bolt to 10 Nm (89 lb in). Page 7642 7. Remove the heater core. Installation Procedure 1. Install the heater core. Page 8979 Console: Service and Repair Front Floor Console Extension Panel Replacement - Left Side Front Floor Console Extension Panel Replacement - Left Side Restraints - Seat Belt Latch Stop Button Availability Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Latch Stop Button Availability INFORMATION Bulletin No.: 07-09-40-002A Date: June 04, 2009 Subject: Seat Belt Latch Stop Button Available for Service Models: 2005-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2 2006-2010 HUMMER H3 2009-2010 HUMMER H3T .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 07-09-40-002 (Section 09 - Restraints). .............................................................................................................................................................. .................................................................................. All seat belt retractor assemblies contain a stop button. If a stop button becomes damaged, the button can be replaced by ordering a replacement button through the GM Parts Catalog. The seat belt retractor assembly does not need replacement. Refer to the Seat Belt Latch Stop Installation procedure in SI for the complete installation procedure. Parts Information For part numbers, usage and availability of stop buttons, see Stop Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6421 Starter Motor X1 Starter Motor X2 (Starter to Battery) (LAT or LE5) Page 9512 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to auto range to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Page 3341 2. Install the APP bolts (1) and tighten to 10 Nm (89 lb in). 3. Connect the APP sensor electrical connector. 4. Confirm that the APP sensor connector locking clip is fully secured. Page 10437 Page 3126 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LAT or LE5 or LE9) Crankshaft Position (CKP) Sensor (LY7) Page 10107 same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. A/C - Front/Rear Passenger Carpet Wet Evaporator Drain Tube: Customer Interest A/C - Front/Rear Passenger Carpet Wet TECHNICAL Bulletin No.: 09-01-37-002D Date: September 27, 2010 Subject: Water Leak into Front and Rear Passenger Floor and/or Carpet Wet (Inspect White Plug in HVAC Evaporator Drain and Apply Sealer to Front of Dash Area) Models: 2008-2010 Chevrolet Cobalt 2008-2011 Chevrolet HHR, Malibu 2008-2010 Pontiac G5 2008-2009 Pontiac G6 2008-2009 Saturn AURA Supercede: This bulletin is being revised to add the Pontiac G5 model. Please discard Corporate Bulletin Number 09-01-37-002C (Section 01 - HVAC). Condition Some customers may comment that the front and rear floor carpet is wet on the passenger side. Cause This condition may be caused by a plugged HVAC evaporator Drain. In some cases, water from the HVAC system will drain back though the front of the dash. Correction Note Reposition of the heat shield is not necessary on a Cobalt and HHR. 1. Verify the customer's concern. If there is water on the passenger side front floor area, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Inspect the operation of the drain. Note Make sure that small debris is not plugging up the drain. 3. Reposition the heat shield (1) in order to gain access to the HVAC drain. Page 5490 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY7 or LZ4 or LZE) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LY7 or LZ4 or LZE) Page 9086 Page 6343 Ignition Coil 3 (LAT or LE5 or LE9) Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 2330 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 674 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 7746 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Page 8267 Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Page 3809 4-3 Shift Solenoid (SS) Valve (ME7 or MN5) Control Solenoid Valve Assembly (MH2) Page 7667 19. Remove the liquid line. Note: Cap all A/C components immediately to prevent system contamination. 20. Remove and discard the sealing washers. Installation Procedure 1. Uncap A/C components. 2. Install new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 3. Install the liquid line. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Page 10063 The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors) * Delphi Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors) * FCI Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors) * Yazaki Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy Page 9931 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Locations Cabin Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component Views Behind Right Side and Center of the Instrument Panel Components 1 - Mode Actuator 2 - Air Temperature Sensor - Upper (C68) 3 - Air Temperature Actuator 4 Recirculation Actuator 5 - Air Temperature Sensor - Lower (C68) Page 4682 12. Connect the right front brake pipe fitting (1) and tighten to 20 Nm (15 lb ft). Note: Ensure the electrical connector is correctly inserted into the EBCM prior to placing the locking lever into position. Failure to make a proper connection may cause communication problems with the module. 13. Connect the EBCM electrical connector. 14. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding). Note: Place the ignition switch in the ON position. Do not start the engine. 15. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). 16. Observe the feel of the brake pedal after performing the diagnostic system check. If the pedal now feels spongy, air may have been in the secondary circuit of the brake modulator assembly, which may have been introduced into the primary circuit. If the pedal feels spongy, perform the Antilock Brake System Automated Bleed (See: Brake Bleeding/Service and Repair/Antilock Brake System Automated Bleed). Page 5596 Sunload Sensor (C68) Sunroof Control Module (CF5) Tire Pressure Monitor - TPM System Message/Service Tips Tires: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat OnStar(R) - Availability for Hearing Impaired Global Positioning System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Body Control Module Fuse: Application and ID Body Control Module Electrical Center Identification Views Body Control Module (BCM) Label Page 5049 1. Install the ground cable. 2. Install the negative battery cable and engine harness leads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the battery cable/ground cable lead nut (2) to the transmission stud. Tighten the nut to 25 Nm (18 lb ft). 4. Install the negative cable to the retainers. 5. Install tape to hold the positive cable to the negative cable. 6. Install the negative battery cable clip to the battery tray. 7. Install the negative cable ground terminal nut at the tie bar and tighten to 10 Nm (89 lb in). 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery Negative Cable Disconnection and Connection). Page 4893 15. Remove the BPMV bolt (1). 16. Remove the BPMV from the bracket (1). 17. Inspect the BPMV bracket insulator for damage and replace, if necessary. 18. If installing a new BPMV, remove the EBCM. Refer to Electronic Brake Control Module Replacement (See: Antilock Brakes / Traction Control Systems/Electronic Brake Control Module/Service and Repair). Installation Procedure Note: When installing a new BPMV, do NOT remove the shipping plugs from the pipe ports until after installation into the vehicle. 1. Install the EBCM, if removed. Refer to Electronic Brake Control Module Replacement (See: Antilock Brakes / Traction Control Systems/Electronic Brake Control Module/Service and Repair). Page 2894 crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. Page 9950 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 2252 Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Right Side Exhaust Manifold Heat Shield Replacement - Right Side Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Remove the bank 1 sensor 1 heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (). 2. Remove the exhaust manifold heat shield bolts. 3. Remove the exhaust manifold heat shield. Installation Procedure Page 1722 Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Special Tools J 43625 Lift Pad Adapter Note: The use of a LOW PROFILE LIFT ARMS SYSTEM may be required to avoid unwanted contact with the vehicle's body and structure depending on lifting equipment used. Refer to the manufacture's recommendation for their applications of low profile lift arms system for their lifting equipment. Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents. Vehicle Lifting - Frame Contact Lift Front Lift Pads Page 6065 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close Page 6135 Fuse 6 .................................................................................................................................................. ................................................................ Emission Fuse 7 ................................................................. ...................................................................................................................... Left Headlamp Low-Beam Fuse 8 ............................................................................................................................... .......................................................................................... Horn Fuse 9 .............................................. ...................................................................................................................................... Right Headlamp Low-Beam Fuse 10 ............................................................................................................ ........................................................................................ Front Fog Lamps Fuse 11 .......................... .......................................................................................................................................................... Left Headlamp High-Beam Fuse 12 .................................................................................................... .............................................................................. Right Headlamp High-Beam Fuse 13 ................... ........................................................................................................................................................... Engine Control Module BATT Fuse 14 ................................................................................................ .................................................................................................. Windshield Wiper Fuse 15 ................ ............................................................................................................................................................. Antilock Brake System (IGN 1) Fuse 16 .............................................................................................. ................................................................................ Engine Control Module IGN 1 Fuse 17 ............... .............................................................................................................................................................. ........................... Cooling Fan 1 Fuse 18 ............................................................................................ ............................................................................................................ Cooling Fan 2 Fuse 19 .................................................................................................................................. Run Relay, Heating, Ventilation, Air Conditioning Blower Fuse 20 ........................................................................ ................................................................................................................. Body Control Module 1 Fuse 21 ................................................................................................................................................ .......................... Body Control Module Run/Crank Fuse 22 ................................................................ ......................................................................................................................... Rear Electrical Center 1 Fuse 23 ............................................................................................................................................. ............................................ Rear Electrical Center 2 Fuse 24 ........................................................... ............................................................................................................................... Antilock Brake System Fuse 25 ................................................................................................................................... ...................................................... Body Control Module 2 Fuse 26 ................................................... .............................................................................................................................................................. ... Starter Fuse 41 ................................................................................................................................ ......................................................... Electric Power Steering Fuse 42 ............................................... .................................................................................................................... Transmission Control Module Battery Fuse 43 .................................................................................................. Ignition Module (LZ4, LZE, LE9 & LE5); Injectors, Ignition Coils Odd (LY7) Fuse 44 ............................................................................................................. Injectors (LZ4, LZE, LE9 & LE5); Injectors, Ignition Coils Even (LY7) Fuse 45 .................................................................................................................................................... Post Cat 02 Sensor Heaters (LY7, LZ4 & LZE) Fuse 46 ............................................................................. .......................................................................................................... Daytime Running Lamps Fuse 47 ......................................................................................................................................................... ................... Center High-Mounted Stoplamp Fuse 50 ........................................................................ ................................................................................................................... Driver Power Window Fuse 51 ................................................................................................................................................ ................................................................ Not Used Fuse 52 ............................................................... .......................................................................................................................................... AIR Solenoid Fuse 54 ................................................................................................................................. ................................................... Regulated Voltage Control Fuse 55 ................................................ ..................................................................................................................................................... DC/AC Inverter Fuse 56 ...................................................................................................................... ......................................................... Antilock Brake System BATT Relays .................................................................................................................................................. ........................................................................ Usage Relay 28 .............................................................................................................................................. ......................................................... Cooling Fan 1 Relay 29 ............................................................. ..................................................................................................................... Cooling Fan Series/Parallel Relay 30 ...................................................................................................................... ................................................................................. Cooling Fan 2 Relay 31 ..................................... .............................................................................................................................................................. ................ Starter Relay 32 .................................................................................................................. ............................................................................ Run/Crank, Ignition Relay 33 .................................. .............................................................................................................................................................. ............ Powertrain Relay 34 ............................................................................................................... ........................................................................ Air Conditioning Clutch Relay 35 ................................ .............................................................................................................................................................. ............. High Beam Relay 36 .............................................................................................................. .................................................................................... Front Fog Lamps Relay 37 ............................. .............................................................................................................................................................. .......................... Horn Relay 38 ........................................................................................................... ............................................................................... Low-Beam Headlamp Relay 39 ........................... .............................................................................................................................................................. .... Windshield Wiper 1 Relay 40 ......................................................................................................... .................................................................................... Windshield Wiper 2 Relay 48 ......................... ............................................................................................................................................................. Daytime Running Lamps Relay 49 ...................................................................................................... ....................................................................................................... Stoplamps Relay 53 .................... .............................................................................................................................................................. ..................... AIR Solenoid Diodes ................................................................................................................................................. ......................................................................... Usage Relay 27 .............................................................................................................................................. ..................................................................... Wiper Page 8446 Disclaimer Page 10544 Page 3178 Heated Oxygen Sensor (HO2S) 1 (LAT or LE5 or LE9 with MN5) Heated Oxygen Sensor (HO2S) 1 (LE5 or LE9 with MH8) Page 4285 Transmission Pressure Test Port: Service and Repair 6T70/6T75 - Automatic Transmission Automatic Transmission Fluid Pressure Test Hole Plug Replacement Page 6051 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 5365 Front Side Door Inside Handle Illumination Lamp Replacement Courtesy Lamp: Service and Repair Front Side Door Inside Handle Illumination Lamp Replacement Front Side Door Inside Handle Illumination Lamp Replacement Page 4640 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Component Location Component Location Component Locations 1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear Support Assembly Page 960 2. Measure from the same end as earlier, and slide the current sensor to that measurement on the negative battery cable. 3. Install the battery negative cable. Refer to Battery Negative Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). Page 3342 Accelerator Pedal: Service and Repair Accelerator Pedal Replacement Accelerator Pedal with Position Sensor Assembly Replacement Removal Procedure 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor bolts (1). 3. Remove the APP sensor (2). Installation Procedure 1. Install the APP sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Locations Steering Angle Sensor: Locations Steering Column Disassembled View 1 - Intermediate Steering Shaft 2 - Intermediate Steering Shaft Bolt 3 - Steering Wheel Position Sensor 4 - Steering Column 5 - Tilt Lever Spring 6 - Tilt Lever Nut 7 - Tilt Lever Bearing 8 - Tilt Lever Spacer 9 - Tilt Lever Retainer 10 - Tilt Lever Retainer 11 - Tilt Lever Cam 12 - Tilt Lever Follower 13 - Tilt Lever 14 - Tilt Lever Spring 15 - Intermediate Steering Shaft Nut Instrument Panel/Center Console Component Views Behind Left Side of the Instrument Panel Components Page 1462 Page 1754 the recommended lubricant. Note: Used roller followers MUST be returned to their original position on the camshaft. If the camshaft is being replaced, the roller followers actuated by the camshaft must also be replaced. 4. Position the camshaft roller followers on the tip of the valve stem and on the lash adjuster. Lubricate the roller followers. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the recommended lubricant. 5. Install the intake camshaft (1) and lubricate. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the recommended lubricant. Page 6346 Ignition Coil 4 (LY7) Page 1403 Fuse Block - Underhood Top View (LZ4 or LZE) Page 2441 Page 9985 * The brake pedal position (BPP) sensor * The On/Off switch The cruise control system will disengage when the brake pedal is applied. The body control module (BCM) monitors the BPP sensor via the BPP sensor signal circuit as the voltage signal increases while the pedal reaches the fully applied position. The ECM monitors the BPP signal through a discrete input and a serial data message signal from the BCM indicating the brake status. When both signals indicate the brake pedal is applied, the ECM will disengage the cruise control system. For further information on the BPP sensor, refer to Exterior Lighting Systems Description and Operation (See: Lighting and Horns/Description and Operation/Exterior Lighting Systems) and to Brake Pedal Position Sensor Calibration (See: Accessories and Optional Equipment/Pedal Positioning System/Pedal Positioning Sensor/Service and Repair/Brake Pedal Position Sensor Calibration). The cruise control system will also disengage when the cruise control on/off switch is switched OFF. The vehicle speed stored in the memory of the engine control module will be erased when the cruise control On/Off switch is turned OFF, or the ignition switch is turned OFF. The BCM sends a serial data message to the ECM in order to disengage the cruise control system. The cruise control system will disengage when the ECM detects that a driver override function has been active for approximately 60 seconds. When the cruise control system has been disengaged, the ECM sends a serial message to the instrument panel cluster (IPC) in order to turn OFF the Cruise Engaged indicator. Every time the cruise control system is disengaged, the ECM will keep track of the reason for system disengagement. The last 8 disengagement reasons will be recorded within the ECM memory. The scan tool will display the last 8 Cruise Disengage History parameters, in which one out of approximately 50 possible reasons will be displayed in each of these 8 parameters. For the disengagement reason to be displayed within the scan tool parameter either the cruise control system is active and disengagement is requested, or engagement of the system is requested but a fault is present. For a list of each disengagement reason along with each definition, refer to Control Module References (See: Testing and Inspection/Programming and Relearning) in the ECM Scan Tool Information. Cruise Control Inhibited The engine control module (ECM) inhibits the cruise control operation when any of the following conditions exist: * The ECM has not detected a brake pedal activation from the body control module (BCM). * A cruise control system DTC has been set. * The vehicle speed is less than 40.2 km/h (25 mph). * The vehicle speed is too high. * The vehicle is in PARK, REVERSE, NEUTRAL, or 1st gear. * The engine RPM is low. * The engine RPM is high. * The system voltage is not between 9 volts and 16 volts. * The Antilock Brake System (ABS)/Traction Control System (TCS) is active for more than 2 seconds. Page 7303 Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application The tire must be in the relaxed position when the repair unit is installed. Do not spread the beads excessively. Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. Page 6616 Fuse Block - Rear Top View Page 4550 Shift Solenoid: Connector Views Component Connector End Views 1-2 Shift Solenoid (SS) Valve (ME7 or MN5) 2-3 Shift Solenoid (SS) Valve (ME7 or MN5) Page 6318 Headlamp - Right Low Beam Page 6085 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 4622 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (ME7 or MN5) Diagrams Air Injection Pump Relay: Diagrams Component Connector End Views Secondary Air Injection (AIR) Pump Relay (NU6) Page 3785 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/4T45-E - Automatic Transmission/Control Valve Body Cover Replacement) 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/4T45-E - Automatic Transmission/Control Valve Body Cover Replacement). Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic Transmission/Transaxle/Description and Operation/4T45-E Automatic Transmission/Transmission Adaptive Functions). Page 1067 Page 6589 Fuse Block - Rear X2 Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 7099 Rear Knuckle: Service and Repair Front Suspension Steering Knuckle Replacement Page 9881 Page 9100 Page 6069 crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. Locations Steering Angle Sensor: Locations Steering Column Disassembled View 1 - Intermediate Steering Shaft 2 - Intermediate Steering Shaft Bolt 3 - Steering Wheel Position Sensor 4 - Steering Column 5 - Tilt Lever Spring 6 - Tilt Lever Nut 7 - Tilt Lever Bearing 8 - Tilt Lever Spacer 9 - Tilt Lever Retainer 10 - Tilt Lever Retainer 11 - Tilt Lever Cam 12 - Tilt Lever Follower 13 - Tilt Lever 14 - Tilt Lever Spring 15 - Intermediate Steering Shaft Nut Instrument Panel/Center Console Component Views Behind Left Side of the Instrument Panel Components Page 6500 Multiple Junction Connector: Diagrams Connector End Views By Number X100 Inline Harness Connector End Views X100 Engine Harness to Transmission Harness (ME7) Page 875 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). 6. Remove the alignment tool. Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 7. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Page 636 Oil Pressure Sender: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (LZ4 or LZE) Engine Oil Pressure (EOP) Switch (LAT or LE5 or LE9) Page 1509 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Page 8793 Door Latch - Passenger Page 6294 Evaporative Emission (EVAP) Canister Vent Solenoid Valve Fo - Ge Component Connector End Views Fog Lamp - Left Front (T96) Page 6279 Engine Control Module (ECM) X2 (LY7) Page 5302 * Use TXL type wire Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6321 Heated Oxygen Sensor (HO2S) 1 (LAT or LE5 or LE9 with MN5) Heated Oxygen Sensor (HO2S) 1 (LE5 or LE9 with MH8) Page 1106 Alignment: Description and Operation Toe Description Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Page 8431 Disclaimer Page 496 Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Replacement Brake Pedal Position Sensor Replacement Page 3640 score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Description and Operation. Page 2516 4. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 5. Install the shift control cable to transaxle range switch lever and verify proper operation. Page 2733 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 245 Page 840 5. Connect the fuel injector wiring harness electrical connector (1) to the MAP sensor. 6. Position the EVAP canister purge tube (1) out of the way. 7. Connect the EVAP canister purge tube to the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 8. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 5701 X480 Inline Harness Connector End Views X480 Rear Lamp Harness to Rear Fascia Harness X495 Inline Harness Connector End Views X495 Rear Lamp Harness to License Lamp Harness Page 9095 Page 5533 Inflatable Restraint Steering Wheel Module Coil X2 Page 2411 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). 2. Ensure that the location measurement of the battery current sensor was recorded for reference during installation. 3. Squeeze the ground ends of the negative battery cable together and remove the sensor (1) from the cable. Installation Procedure Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 1. Install the battery current sensor (1) by passing the ground ends of the negative battery cable through the sensor. Page 7291 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Page 6406 Secondary Air Injection (AIR) Pump Solenoid Bank 1 (LZ4 with NU6, or LZE with NU1 or NU5) Page 168 Page 4758 Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 8. Without disconnecting the hydraulic brake flexible hose, pivot the caliper upward and secure the caliper with heavy mechanics wire (1), or equivalent. 9. Remove the brake pads (2) from the caliper mounting bracket. 10. Push the disc brake caliper piston into the caliper bore using an old inner disc brake pad and a disc brake piston installation tool. Page 4251 4. Remove the transmission mount to bracket through bolt (1). 5. Remove the transmission mount to transmission bolts (1). 6. Remove the transmission mount (2). 7. Disconnect the HO2 sensor Harness from the transmission mount bracket. Page 6096 3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Page 2834 Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Page 3642 7. Remove the 2 control valve body bolts (4) M6 x 65. 8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95. 10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body and transmission control module (TCM) assembly (5). Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 12. Remove the control solenoid valve assembly filter plate (6). * Discard the filler plate. It is not reusable. * Inspect the pressure switch manifold seals for damage or contamination. Replace the control solenoid valve assembly as necessary. * Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage around the PCS seals. Replace the upper channel plate as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (1). Page 9597 Page 8939 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Page 5577 Secondary Air Injection (AIR) Pump Solenoid Bank 1 (LZ4 with NU6, or LZE with NU1 or NU5) Communication Interface Module Replacement Communications Control Module: Service and Repair Communication Interface Module Replacement Communication Interface Module Replacement Page 7988 Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3 or HP7) Page 4800 Note: This procedure is not used in Brazil. 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement) and/or Rear Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement). 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Inspect the friction surfaces of the brake rotor for the following Braking Surface Conditions: * Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be removed by refinishing the rotor. * Cracks and/or heat spots * Excessive blueing discoloration 4. If the friction surfaces of the brake rotor exhibit one or more of the Braking Surface Conditions, the rotor requires refinishing or replacement. 5. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the scoring depth of any grooves present on the rotor friction surfaces. 6. Compare the groove scoring depth recorded to the following specification: Brake rotor maximum allowable scoring: 1.50 mm (0.059 in) 7. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is present, the rotor requires refinishing or replacement. Brake Rotor Thickness Measurement Brake Rotor Thickness Measurement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement) and/or Rear Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement), if equipped. 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the lowest thickness of the brake rotor at 4 or more points, equally spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outside edge of the rotor, about 13 mm (1/2 in), for each measurement. 4. Compare the lowest thickness measurement recorded to the following specifications: Page 9725 Seat Heater: Service and Repair Driver or Passenger Seat Back Cushion Heater Replacement Driver or Passenger Seat Back Cushion Heater Replacement Page 6045 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 5176 Page 8619 1 - Brake Pedal Position (BPP) Sensor 2 - Accelerator Pedal Position (APP) Sensor 3 - Accelerator Pedal 4 - Brake Pedal Page 5461 Engine Coolant Temperature (ECT) Sensor (LZ4 or LZE) Engine Cooling Fan - Left Adjustments Sunroof / Moonroof Panel: Adjustments Sunroof Window Height and Opening Fit Adjustment 1. Open the sunshade. 2. Close the sunroof window. 3. Loosen the 3 adjusting screws on each side of the sunroof window. Page 2236 7. Remove and discard the exhaust manifold nuts (1). 8. Remove the exhaust manifold/catalytic converter assembly (2). 9. Remove and discard the exhaust manifold gasket. Installation Procedure 1. Install a NEW exhaust manifold gasket onto the manifold studs. 2. Install the exhaust manifold/catalytic converter assembly (2). 3. Install the NEW exhaust manifold nuts (1) finger tight. Page 2026 1. Lubricate the solenoid valve O-ring seals with clean engine oil. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the intake (2) CMP actuator solenoid valve and bolt, if required. Tighten the bolt to 10 Nm (89 lb in). 3. Install the exhaust (1) CMP actuator solenoid valve and bolt, if required. Tighten the bolt to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (2) to the intake CMP actuator solenoid valve (3), if required. 5. Connect the engine wiring harness electrical connector (1) to the exhaust CMP actuator solenoid valve (4), if required. 6. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 6306 Garage Door Opener (GDO) (UG1) Capacity Specifications Coolant: Capacity Specifications Cooling System ................................................................................................................................... .................................................. 7.5 quarts (7.1 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 1997 12. Install the friction washer, if applicable. 13. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing. Note: * There are 3 colored links on the timing chain. Two links are of matching color, and 1 link is of a unique color. Use the following procedure to line up the links with the actuators. Orient the chain so that the colored links are visible. * Always use new actuator bolts. 14. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1). Page 5236 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close Page 9438 4. Install the rear upper seat back upper frame bolts (1) and tighten to 35 Nm (26 lb ft). 5. Install the rear seat back bolsters. Refer to Rear Seat Back Cushion Bolster Replacement (See: Service and Repair/Removal and Replacement/Rear Seat Back Cushion Bolster Replacement). Page 977 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Page 2606 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure Caution: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage. 1. Remove the ignition coil(s). Refer to Ignition Coil Replacement (See: Ignition System/Ignition Coil/Service and Repair). Note: Make sure that any water and/or debris is blown out of the spark plug holes prior to removing the spark plugs. 2. Remove the spark plugs using a 5/8 inch spark plug socket. Installation Procedure Page 959 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). 2. Ensure that the location measurement of the battery current sensor was recorded for reference during installation. 3. Squeeze the ground ends of the negative battery cable together and remove the sensor (1) from the cable. Installation Procedure Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 1. Install the battery current sensor (1) by passing the ground ends of the negative battery cable through the sensor. Page 9125 Locations Transmission Temperature Sensor/Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 2263 and Repair/Catalytic Converter Replacement). Exhaust Pipe Heat Shield Replacement Exhaust Pipe Heat Shield Replacement Removal Procedure 1. Remove the exhaust heat shield. Refer to Exhaust Heat Shield Replacement (See: Exhaust Heat Shield Replacement). 2. Remove the exhaust pipe heat shield nuts. 3. Remove the exhaust pipe heat shield. Installation Procedure 1. Position the exhaust pipe heat shield to the underbody. Page 6475 Automatic Transmission Auxiliary Fluid Pump Control Module (HP7 with ME7) Page 6043 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 8210 Page 8756 Front Door Striker: Service and Repair Door Striker Anchor Plate Replacement Removal Procedure Note: This procedure covers the removal and installation of the front and the rear door strikers. It will be necessary to remove the following trim when replacing the front or the rear striker. Note: When the striker bolts have been removed, the striker anchor plate will slip down in the door pillar or quarter panel and the trim will need to be removed to gain access. 1. Remove the body lock pillar lower trim. Refer to Body Lock Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Lower Trim Panel Replacement). 2. Remove the lower center pillar trim. 3. Mark the position of the striker with a grease pencil. 4. Remove the screws from the door striker. 5. Remove the striker (2). Installation Procedure Page 4365 12. Position the cage (2) and the inner race (1) so that the larger radius corners of the cage windows are up. 13. Rotate the inner race 90 degrees to the center line of the cage. 14. Align the lands of the inner race with the windows of the cage. 15. Move the inner race land into the cage window. 16. Rotate the inner race down and remove it from the cage. 17. Clean the following items thoroughly with the proper cleaning solvent: * The inner race * The outer race * The cage * The ball bearings * The exposed end of the wheel drive shaft Important: The internal parts of the CV joint are NOT SERVICED separately. The outer CV joint is serviced as an assembly. 18. If any of the above items are found to have excessive wear or are damaged, replace the outer CV joint as an assembly. Assembly Procedure Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure Important: If replacing the steering wheel position sensor, the new sensor MUST come with a locating pin installed. If a locating pin is not installed, return and reorder a new steering wheel position sensor. Do not apply force to the steering wheel position sensor in a sideways direction. When reusing the steering wheel position sensor you must install a locating pin before removing it from the steering column. If the steering wheel position sensor loses its correct position it must be discarded. The locating pin diameter must be in the range of 1.0-2.0 mm. 1. Set the front wheels in the straight-ahead position and install anti-rotation pin J 42640 in the steering column lower access hole. 2. Disconnect the intermediate steering shaft from the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering/Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 3. Disconnect any electrical connectors as needed. 4. Remove the steering wheel position sensor. Assembly Procedure Page 4905 Brake Master Cylinder: Removal and Replacement Master Cylinder Replacement Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Removal Procedure 1. Without disconnecting the hoses, position the radiator surge tank aside. Refer to Radiator Surge Tank Replacement (See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Radiator Surge Tank Replacement). 2. Deplete the vacuum from the vacuum brake booster by removing the vacuum check valve (1) from the vacuum brake booster grommet (4). Do not disconnect the vacuum check valve (1) from the vacuum brake hose (3). 3. Disconnect the electrical connector from the brake fluid level sensor. Page 7863 Air Bag Control Module: Locations SIR Identification Views The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure, refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Malibu or Maxx 1 - Right Front Impact Sensor-Located under the hood at the front right side of the vehicle 2 - Front Hood Assist Rod-A gas shock located under the front hood on the passenger side 3 - Passenger Instrument Panel Air Bag-Located at the top right under the instrument panel 4 - Right Roof Rail Air Bag-Located under the headliner, extending from the passenger front windshield pillar to the passenger rear windshield pillar 5 - Right Front Side Impact Sensor (SIS)-Located behind door panel on the passenger front door 6 - Inflatable Restraint Sensing and Diagnostic Module (SDM)-Located underneath the vehicle carpet under the center console 7 - Passenger Seat Side Air Bag-Located on the seat back of passenger seat 8 - Passenger Seat Belt Retractor Pretensioner-Located under the trim near the bottom of the center pillar on the passenger side of vehicle 9 - Inflator Module for Right Roof Rail Air Bag-Located behind the garnish molding on the upper rear pillar 10 - Rear Hood Assist Rod-A gas shock located under the rear truck lid on the passenger side 11 - Rear Hood Assist Rod-A gas shock located under the rear truck lid on the driver side 12 - Inflator Module for Left Roof Rail Air Bag-Located behind garnish molding on the upper rear pillar 13 - Driver Seat Belt Retractor Pretensioner-Located under the trim near the bottom of the center pillar on the driver side of vehicle 14 - Driver Seat Side Air Bag-Located on the seat back of driver seat 15 - Left Front Side Impact Sensor (SIS)-Located behind door panel on the driver front door 16 - Left Roof Rail Air Bag-Located under the headliner, extending from the driver front windshield pillar to the driver rear windshield pillar 17 - Driver Steering Wheel Air Bag-Located on the steering wheel 18 - Front Hood Assist Rod-A gas shock located under the front hood on the driver side 19 - Vehicle Battery-Located at the front left of the engine compartment 20 - Left Front Impact Sensor-Located under the hood at the front left side of the vehicle Passenger Compartment/Roof Component Views Roof/Headliner and Under the Center Console Components Page 6170 Fuse Block - Underhood X5 (Battery Positive Cable) (without NVH) Fuse Block - Underhood X6 (Battery Positive Cable) Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 1521 Frequently Asked Questions Disclaimer Page 10122 Cigarette Lighter: Electrical Diagrams Cigar Lighter/Power Outlet Schematics I/P and Center Console Outlet 110V AC Outlet (KV1) Page 3949 Important: Do not manually depress the retaining clip when installing the plastic cap. 10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/6T70/6T75 - Automatic Transmission/Transmission Fluid Level and Condition Check). Service and Repair Rear Door Window Motor: Service and Repair Rear Side Door Window Regulator Motor Replacement Page 6074 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Page 4110 1. Install the 3 input speed sensor seals (1). 2. Install the input speed sensor (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the input speed sensor bolt (2) M6 x 23 and tighten to 12 Nm (106 lb in). 4. Connect the input speed sensor electrical connector (1). 5. Install the transmission control valve body cover. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See: Testing and Inspection/Programming and Relearning/6T30/6T40/6T45 - Automatic Transmission). Page 5554 Park/Turn Signal Lamp - Right Procedures Fuse Block: Procedures Ground Repair Electrical Grounds Proper electrical system function relies on secure, positive, corrosion-free ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacements. In general, electrical ground connections are accomplished using one, or a combination of, three attachment methods: * Welded M6 stud and nut * Welded M6 nut and bolt * Welded M8 nut and bolt Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. Determine which attachment method is used, and carry out the appropriate repair. M6 Weld Stud Replacement 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 5. Select a replacement conductive M6 rivet stud. Refer to GM parts catalog for the correct part number and application. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new rivet stud. 16. Select a new, conductive M6 nut. Refer to GM parts catalog for the correct part number and application. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 17. Install the M6 nut and tighten to 8 Nm (71 lb in). 18. Check for proper system operation. M6 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a new, conductive self-threading M7 bolt may be used to secure the ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive, self-threading M7 bolt Page 109 Accessory Power Outlet - Center Console Page 10089 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 7063 5. If the steering gear has a female rack (5) and a male inner tie rod (1), apply LOCTITE(R) 262, or equivalent, to the threads on the right inner tie rod. 6. Install the right inner tie rod to the rack. 7. Place a pipe wrench on the rack next to the left inner tie rod housing (4). 8. Place a torque wrench and the J-34028 - wrench on the flats of the steering linkage inner tie rod housing (7). Tighten the inner tie rod to 100 Nm (74 lb ft). 9. Place each inner tie rod assembly (2) on a vise. Note: If the steering gear has a female rack (1) and a male inner tie rod (2), do not stake. If the steering gear has a male rack and a female inner tie rod, you must stake. 10. Stake both sides of the 2 female inner tie rod housings to the male rack. 11. Insert a 0.25 mm gauge (1) between the rack (2) and the inner tie rod housing in order to inspect the 4 stakes. The feeler gauge must not pass between the rack and the inner tie rod housing stake. Page 10005 Page 2922 These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U-code. The U-code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the BCM and the scan tool with the low speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. When the scan tool attempts to communicate with the vehicle a No CANdi Module Detected message will be displayed. * An open between the DLC and the BCM will only effect the communication with the scan tool. The vehicle modules will still communicate, and the vehicle will start. * The engine will not start when there is a total malfunction of the low speed GMLAN serial data circuit. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed LAN communications with the scan tool. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank. - Vehicle cranks but will not start. - Vehicle stability enhancement system warning lights and messages. - PRNDL gear indicator position errors. - Tire Pressure Monitor (TPM) system warning light. Reference Information Schematic Reference Data Communication Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Circuit/System Testing Note: Use the schematic to identify the following: * Control modules the vehicle is equipped with * Control module locations on the low speed serial data circuit * Each control modules low speed serial data circuit terminals 1. Attempt to communicate with all control modules on the low speed GMLAN serial data circuit, refer to Data Link References (See: Initial Inspection and Diagnostic Overview). Communications should not be available with two or more control modules on the low speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only, refer to DTC U0100-U02FF (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100). ‹› If one or more control modules are communicating but not all, refer to Testing the Serial Data Circuit for an Open/High Resistance. 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuit terminal 1 and ground. Procedures Seat Belt Tensioner: Procedures Pretensioner Handling and Scrapping Warning When carrying an undeployed inflatable restraint seat belt retractor pretensioner: * Do not carry the seat belt pretensioner by the seat belt webbing or pigtail connector, if equipped. * Carry the seat belt pretensioner by the housing, keeping hands and fingers away from the seat belt webbing. * Make sure the opening, from which the seat belt webbing extends, faces downward and the seat belt webbing hangs freely. Failure to observe these guidelines may result in personal injury. Scrapping Procedure During the course of a vehicles useful life, certain situations may arise which will require the disposal of a live and undeployed seat belt retractor pretensioner. Do not dispose of a live and undeployed seat belt pretensioner through normal disposal channels until the seat belt pretensioner has been deployed. The following information covers the proper procedures for disposing of a live and undeployed seat belt pretensioner. Do not deploy the seat belt retractor pretensioner in the following situations: * After replacement of a seat belt retractor pretensioner under warranty. The seat belt retractor pretensioner may need to be returned undeployed to the manufacturer. * If the vehicle is the subject of a Product Liability report, GM1241, related to the SIR system or the seat belt system. If the vehicle is subject to the Product Liability report, do not alter the SIR or seat belt system in any manner. * If the vehicle is involved in a campaign affecting the seat belt retractor pretensioners. Follow the instructions in the Campaign Service Bulletin for proper SIR handling procedures. Deployment Procedures The seat belt pretensioner can be deployed inside or outside of the vehicle. The method used depends upon the final disposition of the vehicle. Review the following procedures in order to determine which will work best in a given situation. Deployment Inside the Vehicle Refer to Inflatable Restraint Module Handling and Scrapping (See: Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement) for deploying the pretensioner inside vehicle under Vehicle Scrapping Procedure. Deployment Outside Vehicle for Seat Belt Pretensioners Deploy the seat belt pretensioners outside of the vehicle when the vehicle will be returned to service. Situations that require deployment outside of the vehicle include the following: * Using the SIR diagnostics, it is determined that the seat belt pretensioner is malfunctioning. * The seat belt pretensioner pigtail, if equipped, is damaged. * The seat belt retractor pretensioner connector is damaged. * The seat belt retractor pretensioner connector terminals are damaged. Deployment and disposal of a malfunctioning seat belt pretensioner is subject to any required retention period. Warning In order to prevent accidental deployment and the risk of personal injury, do not dispose of an undeployed inflatable restraint seat belt pretensioner as normal shop waste. Undeployed seat belt pretensioners contain substances that could cause severe illness or personal injury if their sealed containers are damaged during disposal. Use the following deployment procedures to safely dispose of an undeployed seat belt pretensioner. Failure to observe the following disposal methods may be a violation of federal, state, or local laws. Special Tools * J 38826 SIR Deployment Harness * J 38826-25 for seat belt pretensioner module adapter * J 39401-B SIR Deployment Fixture * An appropriate pigtail adaptor Page 9124 Page 9896 Page 1278 6. Connect the power steering gear inlet pipe hose retainers. 7. Connect the power steering gear inlet hose to the power steering pump. Tighten the fitting to 27 Nm (20 lb ft). 8. Install the power steering hose bracket (1) and bracket nut (2). Tighten the nut to 5 Nm (45 lb in). Page 1185 Drive Belt: Testing and Inspection Drive Belt Falls Off and Excessive Wear Diagnosis Drive Belt Falls Off and Excessive Wear Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. 13. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley. 14. The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 15. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Page 626 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LAT or LE5 or LE9) Engine Coolant Temperature (ECT) Sensor (LY7) Page 10052 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Page 8230 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Page 9889 Page 5996 Page 3231 Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust (LAT) Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust (LE5 or LE9) Page 8180 Page 9413 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver (LTZ) Seat Adjuster Switch - Driver (AG1) Locations Blower Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (except LAT) Page 1589 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Electrical - Various Electrical Systems Malfunctions Wiring Harness: All Technical Service Bulletins Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Locations Transmission Position Switch/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components (ME7 or MN5) 1 - Park/Neutral Position (PNP) Switch Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure 1. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 2. Disconnect the electrical connector from the park brake warning lamp switch. 3. Remove the park brake warning lamp switch screw (3). 4. Remove the park brake warning lamp switch (2) from the park brake pedal assembly (1). Installation Procedure Page 10367 Headlamp Bulb: Service and Repair Headlamp Bulb Replacement Page 2758 Engine Control Module (ECM) X2 (LAT) Page 10099 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Service and Repair Tail Lamp Control Module: Service and Repair Tail Lamp Control Module with Bulb Replacement Page 4774 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Page 4787 measurement was 0.127 mm (0.005 in), the 0.152 mm (0.006 in) correction plate would be used. 5. Determine the positioning for the correction plate (1) using the high spot mark (3) made during the brake rotor assembled LRO measurement procedure. Note: * Do NOT install used correction plates in an attempt to correct brake rotor assembled LRO. * Do NOT stack up, or install more than one correction plate onto one hub/axle flange location, in an attempt to correct brake rotor assembled LRO. 6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2) orientated to align with the high spot mark (3), that was positioned to face upward. 7. Install the brake rotor to the hub/axle flange. Use the matchmarks made prior to removal for proper orientation to the flange. 8. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 - Conical Brake Rotor Washers (1) and one lug nut (2) onto the upper-most wheel stud. 9. Continue to hold the rotor secure and tighten the lug nut firmly by hand. Page 3234 Variable Valve Timing Solenoid: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (1) from the exhaust camshaft position (CMP) actuator solenoid valve (4), if required. 3. Disconnect the engine wiring harness electrical connector (2) from the intake CMP actuator solenoid valve (3), if required. 4. Remove the exhaust (1) CMP actuator solenoid valve bolt and valve, if required. 5. Remove the intake (2) CMP actuator solenoid valve bolt and valve, if required. 6. Inspect the solenoid valve O-ring seals for damage, replace as necessary. Installation Procedure Page 9113 Page 3725 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual Valve Disassembled Views Disassembled Views Case and Associated Parts Page 4295 3 - Torque Converter Assembly 4 - Manual Shaft and Detent Lever Assembly 5 - 2nd Clutch 6 Reverse Clutch 7 - Coast Clutch 8 - Direct Clutch 9 - Reaction Planetary Gear Set 10 - Input Planetary Gear Set 11 - Forward Clutch 12 - Lo Roller Clutch 13 - Parking Lock Actuator Assembly 14 - Differential and Final Drive Assembly 15 - Output Stub Shaft 16 - Output Speed Sensor 17 Lo/Reverse Servo Assembly 18 - Lo/Reverse Band 19 - Oil Feed Tube Assembly 20 - Input Sprag Clutch Assembly 21 - Oil Filter Assembly 22 - 2nd Roller Clutch 23 - Oil Level Control Valve 24 Drive Link Assembly 25 - Driven Sprocket 26 - Output Shaft 27 - Channel Plate Assembly 28 Input Speed Sensor 29 - 4-3 Solenoid 30 - Drive Sprocket 31 - Control Valve Body Assembly 32 Oil Pump Assembly 33 - Auxiliary Pump Disassembled Views Disassembled Views Case and Associated Parts Page 2852 The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors) * Delphi Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors) * FCI Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors) * Yazaki Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy Engine Controls - MIL ON/DTC P0172 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0172 Set TECHNICAL Bulletin No.: 10-06-04-004A Date: January 13, 2011 Subject: Intermittent Illumination of Malfunction Indicator Lamp (MIL)/Check Engine Light, DTC P0172 Set (Verify Alcohol Content Information in PCM) Models: 2010 Chevrolet Malibu Equipped with 2.4L 4 Cylinder Engine (VINs B, 0 - RPOs LE5, LE9) Please refer to GWM/IVH Supercede: This bulletin is being revised to update the engine type codes. Please discard Corporate Bulletin Number 10-06-04-004 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an intermittent illumination of the malfunction indicator lamp (MIL)/check engine light. Technicians may find a DTC P0172 set. Correction Use the procedure below to determine if the PCM has the incorrect alcohol content information. 1. Verify the actual measured percentage of alcohol content using the J-44175-A tester. Refer to Alcohol in Fuel Diagnosis in SI. If the actual alcohol is less than 15%, determine the "Fuel Alcohol Content" using the Tech 2(R). 2. Install the Tech 2(R) and build the vehicle as a 2010 and select Powertrain. 3. Build the vehicle with an LE9 engine (even if it has the LE5 engine). - Select Special Functions. - Select Fuel System (F2). Page 8178 Page 1510 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 8. Lower the vehicle. Specifications Spark Plug: Specifications Ignition System Specifications Body Rear Corner Upper Garnish Molding Replacement Trim Panel: Service and Repair Body Rear Corner Upper Garnish Molding Replacement Body Rear Corner Upper Garnish Molding Replacement Page 3894 Transmission Control Module (TCM) (MN5 with LZ4 or LZE) Page 9955 Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Page 4625 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). 6. Remove the alignment tool. Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 7. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 9184 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 7966 Ensure that the appropriate wire colors match up (as noted in Step 4) when the connection is made between the seat airbag harness and body harness. 10. Slide all four terminals (2) into the appropriate connector body as shown above. Install the blue terminal position assurance (TPA) devices onto the connector ends. 11. Add NyoGel 760 Lubricant (dielectric lubricant), P/N 12377900 (in Canada, use P/N 10953529) (Saturn retailers, use P/N 12345579) to the terminals on both sides of the connections. 12. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the body harness up to the back of the connector. 13. Reinstall the conduit on the seat airbag harness. 14. Repeat the above procedure on the passenger seat. Reinstall Seats 1. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 2. Reconnect the seat to body harness connector and the seat airbag connector. Reroute Harness and Secure Connector Follow the procedure below to re-route and attach the harness connector to the body harness bundle: 1. The original seat airbag connector was attached with a clip to the bottom of the seat (2) as shown above. 2. Using two wire ties, secure the seat airbag connector to the seat wire bundle as shown. Ensure that there is enough slack for full range of motion of the seat. 3. Inspect the wires through the full range of motion of the seat again as in Step 2. Ensure that the wires have been secured in an orientation that allows full seat motion with adequate clearance to the connectors and sufficient slack in the wires. 4. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 5. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Locations Power Window Switch: Locations Door Component Views Driver Door Components 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Passenger Door Components Page 3859 Shift Solenoid: Service and Repair 6T70/6T75 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/6T70/6T75 Automatic Transmission/Control Valve Body Cover Replacement). 2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3). 5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring (8) to the side. Spring will be released with the removal of the control valve body assembly. Page 1176 Drive Belt: Diagrams Front Wheelhouse Lower Center Panel Replacement Front Fender Liner: Service and Repair Front Wheelhouse Lower Center Panel Replacement Front Wheelhouse Lower Center Panel Replacement Page 5067 2. Measure from the same end as earlier, and slide the current sensor to that measurement on the negative battery cable. 3. Install the battery negative cable. Refer to Battery Negative Cable Replacement (See: Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). Page 10010 Page 3058 Page 6140 FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. ......................................... Passenger Seat Controls Fuse 2 ............................................................... ................................................................................................................................. Driver Seat Controls Fuse 3 ................................................................................................................................... ............................................................................... Not Used Fuse 4 .................................................. .............................................................................................................................................................. .. Not Used Fuse 5 ............................................................................................................................... ......................................... Emission 2, Canister Vent Solenoid Page 4612 2. Install the TFP switch assembly onto the control valve body assembly and install the bolts. Tighten the control valve body bolts to 12 Nm (9 lb ft). 3. Install the transaxle case side cover. 4. Start the engine, warm up the transaxle, and check for leaks. 5. Inspect for proper fluid level. Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 6. Reset the TAP values. Refer to Transmission Adaptive Functions See: Automatic Transmission/Transaxle/Description and Operation. Specifications Wheel Fastener: Specifications Wheel nuts ........................................................................................................................................... ..................................................... 140 Nm (100 lb ft) Page 1392 Body Control Module (BCM) X3 Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 184 Specifications Timing Cover: Specifications Engine front cover ............................................................................................................................... ......................................................... 25 Nm (18 lb ft) Page 9934 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Delphi Connectors Delphi Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 8278 crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. Page 8275 within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) Page 7640 Installation Procedure 1. Install the heater core cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater core cover screws and tighten to 1.5 Nm (13 lb in). 3. Install the center floor air outlet duct. 4. Install the center floor air outlet duct screws and tighten to 1.5 Nm (13 lb in). 5. Install the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Housing Assembly HVAC/Service and Repair). Page 9542 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9579 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the MYLAR tape. If the MYLAR tape is damaged, use 3M product AL-36FR to replace the damaged MYLAR tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Page 2813 Page 5611 Turn Signal/Multifunction Switch X1 Locations Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 10214 For vehicles repaired under warranty use the table above. Disclaimer Service and Repair Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Seal Replacement Removal Procedure 1. Remove the sunroof window panel. Refer to Sunroof Window Replacement (See: Sunroof / Moonroof Panel/Service and Repair). 2. Remove the seal from the window panel frame by pulling the seal away at one point and continuing around the perimeter of the frame. 3. Wipe the perimeter of the frame area with a clean dampened cloth. Allow to air dry. Installation Procedure 1. Using a clean dampened cloth wipe the seal with a small amount of the same window cleaner in order to ease installation. 2. Position the sunroof window panel seal onto the window frame, locating the starting end of the seal at the relief notch in the center of the passenger side of the frame. Important: Ensure that the seal is properly seated around the entire perimeter of the window frame. 3. Firmly press the window seal into place. A small rubber hammer will help in the installation. 4. Install the sunroof window panel. Refer to Sunroof Window Replacement (See: Sunroof / Moonroof Panel/Service and Repair). 5. Adjust the window panel height. Refer to Sunroof Window Height and Opening Fit Adjustment (See: Sunroof / Moonroof Panel/Adjustments). 6. Inspect sunroof for proper operation. Page 3196 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Steering - Front End Clunk/Rattle/Knock On Bumps Stabilizer Link: All Technical Service Bulletins Steering - Front End Clunk/Rattle/Knock On Bumps TECHNICAL Bulletin No.: 06-02-32-007G Date: April 05, 2010 Subject: Clunk, Knock or Rattle Noise From Front of Vehicle While Driving or Turning Over Bumps at Low Speeds (Diagnose Noise and Perform Outlined Repair) Models: 2004-2006 Chevrolet Malibu Maxx 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn Aura Supercede: This bulletin is being revised to update the Parts Information for the bolt. Please discard Corporate Bulletin Number 06-02-32-007F (Section 02 - Steering). Condition 1 Some customers may comment on a clunk noise heard and felt in the steering wheel while driving at slow speeds and turning. The clunk noise may appear to be directly in front of the driver. Hitting a bump while turning can produce the clunk noise. Sometimes the noise may be duplicated when the vehicle is sitting still and the steering wheel is turned 90 degrees in either direction before initially centering the steering wheel. Cause 1 The clunk noise may be caused by a slip/stick condition between the inner and outer components of the intermediate shaft. Important Revised design intermediate shafts went into production in the 2009 model year and are the only design currently available through GMSPO since approximately September 2008. Since any model year vehicle could have had a second design shaft installed, it is critical to identify it before proceeding. The revised design intermediate shafts will NOT tolerate any type of lubricant per the following instructions. Adding lube to the second design shafts will cause a clunk noise in a very short period of time. Use the following pictures to identify which design of shaft you are servicing. Electric Assist Power Steering First Design - Bare Steel Tube (Lube OK) Page 662 Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Refrigerant Pressure Sensor Driver or Passenger Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Knob Replacement Driver or Passenger Seat Adjuster Switch Knob Replacement Page 3160 Manifold Absolute Pressure (MAP) Sensor (LZ4 or LZE) Page 10473 For vehicles repaired under warranty use the table above. Disclaimer Testing and Inspection Wheel Bearing: Testing and Inspection Wheel Bearings Diagnosis Page 2245 4. Pull back the muffler assembly in order to remove the exhaust pipe from the right catalytic converter. 5. Remove and discard the exhaust pipe gasket. Installation Procedure 1. Install a NEW exhaust pipe gasket. 2. Pull back the muffler assembly in order to install the exhaust pipe to the right catalytic converter. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the exhaust pipe to right catalytic converter nuts and tighten to 25 Nm (18 lb ft). 4. Install the exhaust pipe to muffler nuts and tighten to 25 Nm (18 lb ft). 5. Lower the vehicle. Page 1301 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in the vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in the vehicle for five years or 240 000 km (150,000 miles), whichever occurs first. The following explains the cooling system and how to check and add coolant when it is low. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. If using this mixture, nothing else needs to be added. This mixture: Gives freezing protection down to -34°F (-37°C). Gives boiling protection up to 265°F (129°C). Protects against rust and corrosion. Will not damage aluminum parts. Helps keep the proper engine temperature. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system. Page 10297 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 6370 Main Contactor Relay (HP7) X2 Main Contactor Relay (HP7) X3 Manifold Absolute Pressure (MAP) Sensor (LAT or LE5 or LE9) Page 9606 Page 1736 Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust (LAT) Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust (LE5 or LE9) Page 10524 Hazard Warning Switch: Diagrams Component Connector End Views Hazard Warning Switch Page 5036 Locations Transmission Temperature Sensor/Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 4781 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Page 138 Electronic Brake Control Module (EBCM) (LE5 or LE9) Page 9662 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Locations Fluid Pump: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 9875 Page 5743 Fuse Block - Underhood Top View (LZ4 or LZE) Electrical - Various Electrical Concerns/False Messages Door Position Switch: Customer Interest Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Page 3933 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (without LAT or HP7) 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 6236 Courtesy Lamp - Left Front Door Courtesy Lamp - Right Front Door Page 7441 Installation Procedure Note: Align the right air outlet duct to the right outlet duct extension. 1. Install the right air outlet duct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the right air outlet duct screws and tighten to 2.5 Nm (22 lb in). 3. Connect the wire harness clip at the right air outlet duct. 4. Install the right hand side window defogger duct. 5. Install the right hand side window defogger duct screws and tighten to 2.5 Nm (22 lb in). 6. Install the I/P assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 5537 Intake Manifold Tuning (IMT) Solenoid Valve (LY7) Page 7302 Note: Do not install the repair unit in this step. 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Page 5435 Electronic Brake Control Module (EBCM) (LE5 or LE9) Page 1913 4. Install the oil pan bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the 4 oil pan to transaxle bolts and tighten to 75 Nm (55 lb ft). 6. Tighten the oil pan bolts in the sequence shown to 25 Nm (18 lb ft). Page 1120 Alignment: Service and Repair Front Caster Adjustment Front Caster Adjustment The front caster is not adjustable. If the front caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Replace any damaged suspension components as necessary. Page 2964 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 9932 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Page 2931 Knock Sensor (KS) 2 (LZ4 or LZE or LY7) Page 4182 1. Install the transmission shift control (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission shift control nuts (1) and tighten to 25 Nm (18 lb ft). 3. Attach the park lock cable to the shift control base. Ensure the park lock cable retainer (2) is fully secured to the shift control base. 4. Install the park lock cable on the park lock lever by sliding the cable end (1) over the park lock lever pin. Page 5814 Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information 1. Submit a transaction using the table below. * The amount identified in the Net Item column should represent the actual cost of the woven polyester electrical tape, required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a customer satisfaction program that affects your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle. Page 9736 Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 6395 Seat Adjuster Switch - Driver (without LTZ and AG1) Page 5240 crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. Page 8591 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Engine Compartment Fuse Block - Owners Manual Fuse: Locations Engine Compartment Fuse Block - Owners Manual ENGINE COMPARTMENT FUSE BLOCK The vehicle may not be equipped with all the fuses and features listed. The engine compartment fuse block is located on the driver side of the engine compartment, near the battery. Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the covers on any electrical component. Page 4874 Note: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length. 6. Using the pipe cutter included in the J 45405, carefully cut the brake pipe squarely to the measured length. 7. Remove the sectioned brake pipe from the vehicle. 8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size. 9. Strip the nylon coating from the brake pipe end to be flared, if necessary. * Select the appropriate blade on the coating stripping tool included in the J 45405, by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. - 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe * Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. * While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. Note: Do not gouge the metal surface of the brake pipe. * Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. * After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. * Loosen the thumbwheel of the tool and remove the brake pipe. Note: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. * Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. - 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe - 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe Page 4986 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 858 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Page 1520 Page 986 Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor (NVH) Page 6497 Brake Fluid Level Switch Brake Master Cylinder Pressure Sensor (LAT) Page 3162 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 3. Reposition the EVAP canister purge tube (1) out of the way. 4. Disconnect the fuel injector wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor. Page 4212 Page 7655 Heater Hose: Service and Repair Heater Outlet Hose Replacement - Heater Core to Connector Heater Outlet Hose Replacement - Heater Core to Connector Page 4257 2. Remove the transmission mount bracket to frame bolts (1). 3. Remove the transmission mount bracket (2). Installation Procedure 1. Install the transmission mount bracket (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission bracket to frame bolts (1) and tighten to 50 Nm (37 lb ft). 3. Install the rear transmission mount. Refer to Transmission Rear Mount Replacement (See: Transmission Rear Mount Replacement). Transmission Mount Replacement - Left Side Transmission Mount Replacement - Left Side Removal Procedure 1. Remove the battery and tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair). 2. Using a floor jack and a block of wood, support the powertrain. Page 2305 Body Control Module: Service and Repair Body Control Module Replacement Page 348 Engine Control Module: Description and Operation Engine Control Module Description The engine control module (ECM) interacts with many emission related components and systems, and monitors the emission related components and systems for deterioration. OBD II diagnostics monitor the system performance and a diagnostic trouble code (DTC) sets if the system performance degrades. The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type. A DTC is ranked as a Type A or Type B if the DTC is emissions related. Type C is a non-emissions related DTC. The ECM is in the engine compartment. The ECM is the control center of the engine controls system. The ECM controls the following components: * The fuel injection system * The ignition system * The emission control systems * The on-board diagnostics * The A/C and fan systems * The throttle actuation control (TAC) system The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect the vehicle performance and the emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the MIL. When the ECM detects a malfunction, the ECM stores a DTC. The condition area is identified by the particular DTC that is set. This aids the technician in making repairs. ECM Function The engine control module (ECM) can supply 5 V or 12 V to the various sensors or switches. This is done through pull-up resistors to the regulated power supplies within the ECM. In some cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is too low. Therefore, a DMM with at least 10 Mohm input impedance is required in order to ensure accurate voltage readings. The ECM controls the output circuits by controlling the ground or the power feed circuit through the transistors or a device called an output driver module. EEPROM The electronically erasable programmable read only memory (EEPROM) is a permanent memory that is physically part of the engine control module (ECM). The EEPROM contains program and calibration information that the ECM needs in order to control the powertrain operation. Special equipment, as well as the correct program and calibration for the vehicle, are required in order to reprogram the ECM. Data Link Connector (DLC) The data link connector (DLC) is a 16-pin connector that provides the technician a means of accessing serial data for aid in the diagnosis. This connector allows the technician to use a scan tool in order to monitor the various serial data parameters, and display the DTC information. The DLC is located inside of the drivers compartment, underneath the dash. Malfunction Indicator Lamp (MIL) The malfunction indicator lamp (MIL) is inside of the instrument panel cluster (IPC). The MIL is controlled by the engine control module (ECM) and illuminates when the ECM detects a condition that affects the vehicle emissions. ECM Service Precautions The engine control module (ECM), by design, can withstand the normal current draws that are associated with the vehicle operations. However, care must be used in order to avoid overloading any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the ECM circuits unless the diagnostic procedure instructs you to do so. These circuits should only be tested with a DMM. Emissions Diagnosis For State I/M Programs This OBD II equipped vehicle is designed to diagnose any conditions that could lead to excessive levels of the following emissions: * Hydrocarbons (HC) * Carbon monoxide (CO) * Oxides of nitrogen (NOx) Page 8258 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Page 5821 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6650 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7475 Air Register: Service and Repair Instrument Panel Center Air Outlet Replacement Instrument Panel Center Air Outlet Replacement Interior - Instrument Panel Top Cover Appears Warped Air Register: Customer Interest Interior - Instrument Panel Top Cover Appears Warped TECHNICAL Bulletin No.: 08-08-49-004A Date: July 15, 2009 Subject: IP Upper Trim Panel Top Cover Appears Warped (Seat Retaining Clips) Models: 2008-2010 Chevrolet Malibu Supercede: This bulletin is being revised to add model years and to update the labor operation description. Please discard Corporate Bulletin Number 08-08-49-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the instrument panel (IP) upper trim top cover "defroster grille" appears warped. Cause The retaining clips may not be properly seated, causing the clips to push the IP upper trim panel up. Correction Remove the IP upper trim panel and seat the retaining clips using the steps below. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. 2. Remove the windshield pillar garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement in SI. 3. Remove the IP upper trim panel. Refer to IP Upper Trim Panel Replacement in SI. 4. Inspect the slot of the retaining clip that was not properly seated for any flashings or obstructions. - Clean the retaining clip slot. - Make sure the anti-squeak tape is still in position on the carrier after inspection. Tip A sharp rap with your hand at each retainer location may help seat the retaining clips. 5. Install the IP upper trim panel starting with the clip that was not properly retained first. Ensure the clip is fully seated. 6. Finish installing the remaining IP upper trim panel clips making sure all the retaining clips are fully seated. Important If the IP upper trim panel was raised at the end, make sure that the end clip is still seated. The garnish molding installation may cause the end clip to release if the clip was not fully engaged into the slot. DO NOT pinch the speaker electrical wires. 7. Install the windshield pillar garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement in SI. 8. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 10619 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Right Side Front Side Door Window Switch Replacement - Right Side Page 6576 Fuse Block - Underhood X2 Page 2566 Knock Sensor (KS) 2 (LZ4 or LZE or LY7) Page 8320 Disclaimer Page 1123 1. Reach around the tire, using the appropriate extension and socket. 2. Loosen both strut to knuckle nuts just enough to allow for movement. 3. If the strut has not been modified previously, perform the following steps before continuing with the wheel alignment: 1. Disconnect the strut from the knuckle. Refer to Strut Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Strut/Strut Assembly Replacement). Page 8881 Trunk / Liftgate Switch: Diagrams Component Connector End Views Rear Compartment Lid Release Switch 6T30/6T40/6T45 - Automatic Transmission Transmission Speed Sensor: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Output Speed Sensor Replacement Output Speed Sensor Replacement Input Speed Sensor Replacement Input Speed Sensor Replacement Removal Procedure 1. Remove the transmission control valve body cover. Page 1851 Drive Belt: Service Precautions Belt Dressing Caution Caution: Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt. Page 7887 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement Inflatable Restraint Side Impact Sensor Replacement Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Page 438 Note: Rotate the pigtail 90 degrees from vertical before securing the fastener. 1. Install the knock sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the knock sensor bolt and tighten to 25 Nm (18 lb ft). 3. Install the knock sensor electrical connector pigtail (6) clip to the oil level indicator tube bracket. 4. Connect the engine wiring harness electrical connector (1) to the knock sensor pigtail electrical connector (6). 5. Lower the vehicle. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Electrical - Various Electrical Concerns/False Messages Door Switch: All Technical Service Bulletins Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Page 10638 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 7855 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 3084 Locations Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views Wheel Components 1 - Wheel Speed Sensor (WSS) - Right Front 2 - Wheel Speed Sensor (WSS) - Right Rear 3 Wheel Speed Sensor (WSS) - Left Rear 4 - Wheel Speed Sensor (WSS) - Left Front Page 10151 For vehicles repaired under warranty use the table above. Disclaimer Page 8211 Page 3817 2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid valve spring (7) into position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Install all bolts before tightening, then tighten in specified sequence. 4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x 55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6 x 42. 8. Install the 2 control valve body bolts (4) M6 x 65 and tighten to 12 Nm (106 lb in). 9. Connect the input speed sensor electrical connector (1). 10. Connect the output speed sensor electrical connector (2). 11. Connect the shift position switch electrical connector (3). 12. Install the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Page 9408 Power Seat Motor: Service and Repair Front Seat Recliner Actuator Motor Replacement Front Seat Recliner Actuator Motor Replacement Page 9545 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 10170 Page 4837 6. If any of the conditions listed are found, the disc brake pad retainers require replacement. 7. Remove the brake caliper mounting bracket bolts (1). 8. Remove the brake caliper bracket from the steering knuckle. 9. Inspect the caliper bracket (5). If the brake caliper bracket (5) is bent, cracked, or damaged, it requires replacement. 10. Inspect the brake caliper guide pins (2) for freedom of movement, and inspect the condition of the guide pin boots (4). Move the brake caliper guide pins (2) inboard and outboard within the brake caliper bracket (5), without disengaging the slides from the boots, and observe for the following: * Restricted caliper guide pin movement * Looseness in the brake caliper mounting bracket * Seized or binding caliper guide pins * Split or torn boots 11. If any of the conditions listed are found, the brake caliper guide pins (2) and/or boots (4) require replacement. Page 5793 Fuse Block - Rear X3 Page 4620 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH8) Page 3947 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure Important: * Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. * Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. * Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 1. Install a new retaining ring into the quick connect fitting using the following procedure: 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. Page 10814 Wiper Switch: Diagrams Component Connector End Views Windshield Wiper/Washer Switch Page 1806 19. Install a straight edge on the cylinder block perpendicular to the crankshaft centerline. 20. Using a light, illuminate the backside of the straight edge. 21. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side of both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed. Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 9703 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 137 Page 4880 5. Disconnect the brake pipe fitting (1) from the brake hose (3). Cap or plug the brake pipe fitting end and the brake hose end to prevent fluid loss and contamination. 6. Remove the brake hose retainer (2). 7. Remove the brake hose nut (4) attaching the hose to the strut. 8. Remove the brake hose-to-caliper bolt (1) from the brake caliper. 9. Remove the brake hose (3) from the brake caliper. 10. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end. 11. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. Installation Procedure Page 9532 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Bosch Connectors Bosch Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 1402 Fuse Block - Underhood Top View (LY7) Page 5750 Page 2426 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Exhaust Camshaft Position Sensor Replacement - Exhaust Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (5) from the exhaust camshaft position (CMP) sensor (4). 3. Remove the CMP sensor bolt. (Intake CMP shown, exhaust CMP similar). 4. Remove the CMP sensor. Installation Procedure Page 3129 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor. Installation Procedure Locations Cabin Temperature Sensor / Switch: Locations Instrument Panel/Center Console Component Views Behind Right Side and Center of the Instrument Panel Components 1 - Mode Actuator 2 - Air Temperature Sensor - Upper (C68) 3 - Air Temperature Actuator 4 Recirculation Actuator 5 - Air Temperature Sensor - Lower (C68) Page 4928 Parking Brake Release Switch: Diagrams Component Connector End Views Park Brake Switch Page 7529 Page 5343 Fuse: Application and ID Fuse Block - Rear Electrical Center Identification Views Fuse Block - Rear Label Page 5189 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Page 5730 Page 8540 Disclaimer Page 6799 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Locations Transmission Speed Sensor: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH2) Page 3900 Automatic Transmission/Control Valve Body Cover Replacement). 13. If a NEW TCM has been installed into the vehicle, the NEW module needs to be reprogrammed. Refer to Service Programming System (SPS) ( See: Testing and Inspection/Programming and Relearning/Service Programming System (SPS)). Note: The Service Fast Learn Adapts procedure must be performed when one of the following repairs have been made to the vehicle. Failure to perform the procedure after one of the following repairs may result in poor transmission performance, as well as transmission DTCs being set: * Transmission internal service/overhaul * Valve body repair or replacement * Control solenoid valve assembly replacement * TCM software/calibration update * Any service in response to a shift quality concern 14. Perform the Service Fast Learn Adapts. Refer to Service Fast Learn Adapts (See: Testing and Inspection/Programming and Relearning/6T70/6T75 - Automatic Transmission). Page 3617 4. Remove the shift lock control solenoid. Installation Procedure 1. Route the shift lock control solenoid through the opening in the front of the control assembly. Page 5082 Generator X2 (LE5 or LE9) Generator X2 (LY7) Specifications Flywheel: Specifications Flywheel .............................................................................................................................................. ........................................... 53 Nm (39 lb ft) plus 25° Page 5594 Steering Wheel Control Switch - Right (UK3) Page 5342 Page 5788 Fuse Block - Rear Bottom View Page 9164 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wire dress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 6310 Generator Battery 1 (-) (HP7) Generator Battery 1 (+) (HP7) Generator Battery 2 (-) (HP7) Generator Battery 2 (+) (HP7) Generator Battery 3 (-) (HP7) Locations Knock Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Lower Front and Rear of the Engine Components (LY7) Locations Impact Sensor: Locations SIR Identification Views The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure, refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Malibu or Maxx 1 - Right Front Impact Sensor-Located under the hood at the front right side of the vehicle 2 - Front Hood Assist Rod-A gas shock located under the front hood on the passenger side 3 - Passenger Instrument Panel Air Bag-Located at the top right under the instrument panel 4 - Right Roof Rail Air Bag-Located under the headliner, extending from the passenger front windshield pillar to the passenger rear windshield pillar 5 - Right Front Side Impact Sensor (SIS)-Located behind door panel on the passenger front door 6 - Inflatable Restraint Sensing and Diagnostic Module (SDM)-Located underneath the vehicle carpet under the center console 7 - Passenger Seat Side Air Bag-Located on the seat back of passenger seat 8 - Passenger Seat Belt Retractor Pretensioner-Located under the trim near the bottom of the center pillar on the passenger side of vehicle 9 - Inflator Module for Right Roof Rail Air Bag-Located behind the garnish molding on the upper rear pillar 10 - Rear Hood Assist Rod-A gas shock located under the rear truck lid on the passenger side 11 - Rear Hood Assist Rod-A gas shock located under the rear truck lid on the driver side 12 - Inflator Module for Left Roof Rail Air Bag-Located behind garnish molding on the upper rear pillar 13 - Driver Seat Belt Retractor Pretensioner-Located under the trim near the bottom of the center pillar on the driver side of vehicle 14 - Driver Seat Side Air Bag-Located on the seat back of driver seat 15 - Left Front Side Impact Sensor (SIS)-Located behind door panel on the driver front door 16 - Left Roof Rail Air Bag-Located under the headliner, extending from the driver front windshield pillar to the driver rear windshield pillar 17 - Driver Steering Wheel Air Bag-Located on the steering wheel 18 - Front Hood Assist Rod-A gas shock located under the front hood on the driver side 19 - Vehicle Battery-Located at the front left of the engine compartment 20 - Left Front Impact Sensor-Located under the hood at the front left side of the vehicle Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (1 of 2) Page 3509 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor - Bank 1 Exhaust (LY7) Camshaft Position (CMP) Sensor - Bank 1 Intake (LY7) Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 3037 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Locations Steering Angle Sensor: Locations Steering Column Disassembled View 1 - Intermediate Steering Shaft 2 - Intermediate Steering Shaft Bolt 3 - Steering Wheel Position Sensor 4 - Steering Column 5 - Tilt Lever Spring 6 - Tilt Lever Nut 7 - Tilt Lever Bearing 8 - Tilt Lever Spacer 9 - Tilt Lever Retainer 10 - Tilt Lever Retainer 11 - Tilt Lever Cam 12 - Tilt Lever Follower 13 - Tilt Lever 14 - Tilt Lever Spring 15 - Intermediate Steering Shaft Nut Instrument Panel/Center Console Component Views Behind Left Side of the Instrument Panel Components Page 2130 2. Install the heater core cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the heater core cover screws and tighten to 1.5 Nm (13 lb in). 4. Install the center floor air outlet duct. 5. Install the upper floor air outlet duct screws and tighten to to 1.5 Nm (13 lb in). 6. Install the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair). Page 7079 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the bolt and nut from the trailing arm bracket to the trailing arm. Tighten the trailing arm to bracket nut to 60 Nm (44 lb ft). Using the J 45059 rotate the nut an additional 60 degrees. 2. Position the trailing arm and bracket assembly (2) on the knuckle (1) and the frame (3). Page 5148 Page 821 1. Install the MAF/IAT sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1) and tighten to 2.5 Nm (22 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor (2). Page 1447 Fuse Block - Underhood Bottom View Page 8137 Installation Procedure 1. Install the cable to the vehicle. 2. Connect the cable to the communications module. 3. Connect the cable to the antenna. 4. Install the right closeout panel. Refer to Instrument Panel Insulator Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement Right Side). 5. Install the headliner to the vehicle. Refer to Headlining Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). Page 4374 6. Slide the tripot joint spider assembly (4) as far as it will go on the halfshaft bar. 7. Install the spacer ring (2) into the groove of the halfshaft bar J 8059. Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 9609 Page 5436 Page 1850 Drive Belt: Diagrams Catalytic Converter Replacement Catalytic Converter: Service and Repair Catalytic Converter Replacement Catalytic Converter Replacement Removal Procedure 1. Remove the heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 2 (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor Replacement Sensor 2). 2. Remove the catalytic converter to exhaust manifold nuts (1). 3. Remove the catalytic converter to muffler nuts (1). 4. Separate the exhaust pipe from the catalytic converter studs. 5. Position and support the exhaust pipe out of the way. 6. Remove the catalytic converter (2) and gasket. Page 904 Page 7290 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage Page 3997 Important: Ensure the ignition key is in the RUN position. Do NOT attempt to remove the park lock cable with the key in any other position. 8. Using a screwdriver, release the cable from the ignition switch inhibitor by depressing the cable latch (1). 9. Remove the park lock cable from the inhibitor housing. 10. Attach a long piece of mechanics wire to the end of the park lock cable before removing the cable. The wire will assist with installation of the new cable. 11. Remove the park lock cable from the vehicle. 12. Remove the mechanics wire from the park lock cable. Installation Procedure 1. Attach the mechanics wire to the park lock cable in order to assist with installation of the cable. 2. Install the park lock cable to the vehicle. 3. Remove the mechanics wire from the park lock cable. 4. Ensure the shift lever is in the PARK position. 5. Ensure that the ignition key is in the RUN position. Page 4000 Important: Ensure the ignition key is in the RUN position. Do NOT attempt to remove the park lock cable with the key in any other position. 8. Using a screwdriver, release the cable from the ignition switch inhibitor by depressing the cable latch (1). 9. Remove the park lock cable from the inhibitor housing. 10. Attach a long piece of mechanics wire to the end of the park lock cable before removing the cable. The wire will assist with installation of the new cable. 11. Remove the park lock cable from the vehicle. 12. Remove the mechanics wire from the park lock cable. Installation Procedure 1. Attach the mechanics wire to the park lock cable in order to assist with installation of the cable. 2. Install the park lock cable to the vehicle. 3. Remove the mechanics wire from the park lock cable. 4. Ensure the shift lever is in the PARK position. 5. Ensure that the ignition key is in the RUN position. Page 6414 Speaker - Right Rear (UQA) Speaker - Right Rear (UQ3) Page 6606 Fuse Block - Underhood X1 Page 4794 7. Install the brake rotor to the hub/axle flange. Use the matchmarks made prior to removal for proper orientation to the flange. 8. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 - Conical Brake Rotor Washers (1) and one lug nut (2) onto the upper-most wheel stud. 9. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 10. Install the remaining CH-45101-100 - Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 11. Using the CH-39544-KIT - Complete Torque Socket Set - 10 PCS, or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 12. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 14. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Page 9757 For vehicles repaired under warranty use the table above. Disclaimer Page 8848 Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Handle Replacement Hood Primary Latch Release Cable Handle Replacement Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 5100 Disclaimer Page 4960 Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) (LAT) Page 9296 Heated Seat Control Module - Passenger X2 (KA1) Page 4103 1 - Control Valve Body Cover Assembly 2 - Transmission Fluid Level Indicator Assembly 3 - Fluid Level Indicator Tube - Model Dependent 4 - Fluid Level Indicator Tube Seal - Model Dependent 5 Control Valve Body Cover Assembly Gasket 6 - Control Valve Body Cover Stud 7 - Control Valve Body Cover Bolt 8 - Control Valve Body Bolt 9 - Control Valve Body Bolt 10 - Control Valve Body Cover Wiring Connector Hole Seal 11 - Control Solenoid Valve Spring 12 - Control Valve Body Bolt 13 - Control Valve Body Bolt 14 - Control Valve Body Bolt 15 - Control Solenoid (w/Body and TCM) Valve Assembly 16 - Control Solenoid (w/Body and TCM) Filter Plate Assembly 17 - Manual Shaft Detent Assembly 18 - Control Valve Body Assembly 19 - A/Trans Output Speed Sensor Assembly 20 - A/Trans Output Speed Sensor Bolt 21 - A/Trans Case Assembly 22 - Torque Converter Housing Outer Seal 23 - Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly 24 Front Differential Drive Pinion Gear Lube Tube Page 1070 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Right Side Front Side Door Window Switch Replacement - Right Side Page 4808 4. Install the brake rotor to the hub/axle flange. Use the matchmarks made prior to removal for proper orientation to the flange. 5. Install the brake caliper mounting bracket an caliper as an assembly to the suspension knuckle. Refer to Rear Brake Caliper Bracket Replacement (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement). 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing (See: Brake Pad/Service and Repair/Procedures). Page 6811 Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Procedures Brake Master Cylinder: Procedures Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Master Cylinder Reservoir Filling). 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only GM approved brake fluid from a clean, sealed brake fluid container. Page 3357 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 5525 Inflatable Restraint Roof Rail Module - Left Inflatable Restraint Roof Rail Module - Right Page 1761 9. Remove the upper timing chain guide bolts and guide. 10. Remove the timing chain tensioner. Page 6419 Starter Generator Control Module (SGCM) X3 (LAT) Page 7286 Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Page 2100 Coolant Outlet: Service and Repair Water Outlet Replacement Water Outlet Replacement Page 6411 Speaker - Left Rear (UQ3) Speaker - Left Rear (UW5) Page 6879 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). Procedures Fuse Block: Procedures Ground Repair Electrical Grounds Proper electrical system function relies on secure, positive, corrosion-free ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacements. In general, electrical ground connections are accomplished using one, or a combination of, three attachment methods: * Welded M6 stud and nut * Welded M6 nut and bolt * Welded M8 nut and bolt Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. Determine which attachment method is used, and carry out the appropriate repair. M6 Weld Stud Replacement 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 5. Select a replacement conductive M6 rivet stud. Refer to GM parts catalog for the correct part number and application. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new rivet stud. 16. Select a new, conductive M6 nut. Refer to GM parts catalog for the correct part number and application. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 17. Install the M6 nut and tighten to 8 Nm (71 lb in). 18. Check for proper system operation. M6 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a new, conductive self-threading M7 bolt may be used to secure the ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive, self-threading M7 bolt Windshield Washer Solvent Container Filler Tube Replacement Windshield Washer Reservoir: Service and Repair Windshield Washer Solvent Container Filler Tube Replacement Windshield Washer Solvent Container Filler Tube Replacement Page 9121 Page 6583 Relay Box: Locations Fuse Block - Rear Electrical Center Identification Views Fuse Block - Rear Label Page 7520 5. Remove the compressor clutch plate from the compressor. 6. Remove the compressor pulley snap ring using the J 6083. Page 6381 Park/Neutral Position (PNP) Switch (ME7 or MN5) Page 637 Engine Oil Pressure (EOP) Switch (LY7) Page 6569 Fuse Block - Underhood Top View (LAT) Page 6785 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Exploded Views Transmission Speed Sensor: Exploded Views Disassembled Views Disassembled Views Case and Associated Parts (1 of 3) 1 - Side Cover (Structural) 2 - Axle Oil Seal 3 - Side Cover Bolt 4 - Side Cover Stud 5 - Side Cover Gasket 6 - Side Cover Oil Level Control Gasket 7 - Thrust Washer (Side Cover to Driven Sprocket) 8 - Oil Pump Bolt 9 - Oil Pump Bolt 10 - Transaxle Oil Pump Assembly 11 - Transaxle Wiring Assembly 12 - TFP Manual Valve Position Switch Assembly Bolt 13 - TFP Manual Valve Position Switch Assembly 14 - Wiring Harness Pass-Through Connector O-Ring Seal 15 - Wiring Harness Bracket Bolt/Input Speed Sensor Bolt 51 - Transaxle Case 52 - Vent Cap 55 - Torque Converter Assembly 61 - Output Speed Sensor Stud 62 - Output Shaft Speed Sensor 63 - O-Ring Seal (Output Speed Sensor) 64 - Band Anchor Pin (Lo/Reverse) 65 - Oil Level Control Plug 81 - Tube Assembly Bolt/Bottom Pan Bolt 84 - Transaxle Oil Filter Seal Page 1595 Tires: Description and Operation P-Metric Sized Tires Description P-Metric Sized Tires Description Most P-metric tire sizes do not have exact corresponding alphanumeric tire sizes. Replacement tires should be of the same tire performance criteria TPC specification number including the same size, the same load range, and the same construction as those originally installed on the vehicle. Consult a tire dealer if you must replace the P-metric tire with other sizes. Tire companies can best recommend the closest match of alphanumeric to P-metric sizes within their own tire lines. The above illustration may not correspond with your vehicle, but is meant as an example. Page 8232 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Page 3905 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Secure the 12 control valve body bolts (2) M6 x 97 and tighten in sequence to 10 Nm (89 lb in). 5. Secure the 3 control valve body bolts (1) M5 x 40.5 and tighten in sequence to 8 Nm (71 lb in). 6. Connect the input speed sensor electrical connector (1). 7. Connect the output speed sensor electrical connector (2). 8. Connect the shift position switch electrical connector (3). 9. Install the transmission control valve body cover. 10. If a NEW TCM has been installed into the vehicle, the NEW module needs to be reprogrammed. Refer to Service Programming System (SPS) ( See: Testing and Inspection/Programming and Relearning/Service Programming System (SPS)). Note: The Service Fast Learn Adapts procedure must be performed when one of the following repairs have been made to the vehicle. Failure to perform the procedure after one of the following repairs may result in poor transmission performance, as well as transmission DTCs being set: * Transmission internal service/overhaul * Valve body repair or replacement * Control solenoid valve assembly replacement * TCM software/calibration update * Any service in response to a shift quality concern 11. Perform the Service Fast Learn Adapts. Refer to Service Fast Learn Adapts (See: Testing and Inspection/Programming and Relearning/6T30/6T40/6T45 - Automatic Transmission). Page 9483 Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Page 9158 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Page 6511 Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure 1. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 2. Disconnect the electrical connector from the park brake warning lamp switch. 3. Remove the park brake warning lamp switch screw (3). 4. Remove the park brake warning lamp switch (2) from the park brake pedal assembly (1). Installation Procedure Page 817 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 3913 Fluid - A/T: Fluid Type Specifications Automatic Transmission DEXRON-VI Automatic Transmission Fluid. Page 7553 connector housing. Refer to Repairing Connector Terminals in SI. 15. Insert the wire into the new conduit and tape the conduit end at the connector. Tape the conduit closed every 255 mm (10 in) with electrical tape. 16. Connect the fan end electrical connector into the cooling fan. 17. Fasten the new wire and conduit with tie wraps (GM P/N 12337820), as shown below. At the cooling fan end of the wire and conduit, leave adequate slack to allow for engine movement (white tie wraps are used for display purposes, use black tie wraps to match the original appearance). With RPO LY7 - Fasten the new wire and conduit to the existing harness with wire tie wraps as shown. With RPOs LZ9, LZ4 or LZE - Fasten the new wire and conduit to metal the transmission cooler lines as shown. (The lower cover has been removed to show the location of the wire tie wraps.) 18. Trim the wire and conduit to length at the underhood fuse block area. 19. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 20. Strip the wire insulation as required and install the terminal, GM P/N 15324340, on the wire. Refer to Repairing Connector Terminals in SI. 21. Reinstall the terminal into A2 on the junction block. Reinstall the TPA and the harness back cover. 22. Reconnect the harness to the under hood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 23. Reinstall the underhood fuse block into it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. Install the 40-amp fuse, GM P/N 15319478. 24. Reinstall the battery. Refer to Battery Replacement in SI. 25. Reinstall the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 26. Reinstall the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 27. Confirm the high speed cooling fan operation using the Tech 2(R). Parts Information Page 1762 Note: * The intake camshaft actuator should not rotate during the removal or installation. * Ensure the tips of the tool are fully engaged into the timing chain. The retention tool rod can be used on the back side of the chain to ensure the teeth from the retention tool are engaged. 11. Install the EN-48749 - retention tool (1) to the intake side of the timing chain. 12. Install the EN-48749 - retention tool (1) to the exhaust side of the timing chain. 13. Remove and discard the intake camshaft actuator bolt (1). 14. Rotate the exhaust camshaft clockwise slightly to take the tension off of the timing chain on the intake actuator. 15. Remove the intake camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain. Installation Procedure Locations Auxiliary Power Outlet: Tools and Equipment Special Tools Page 3395 value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest individual fuel injector resistance value from the average resistance value. Compute the difference between the highest individual fuel injector resistance value and the average resistance value. Replace the fuel injector that displays the greatest difference above or below the average. AFIT Test Procedure Note: DO NOT perform the AFIT Test Procedure if the ECT is above 94°C (201°F). Irregular fuel pressure readings may result due to hot soak fuel boiling. Note: Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic. 1. Turn OFF all accessories. 2. Turn OFF the ignition. 3. Install the AFIT. Refer to the AFIT User Guide. 4. Turn ON the AFIT and select the vehicle. 5. Turn ON the ignition and perform the Injector Test. ‹› If the AFIT aborts testing due to fuel pressure or fuel leak down, refer to Fuel System Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel System Diagnosis). 6. View the test results. ‹› If any injector exceeds the recommended tolerance, replace the injectors. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Fuel Injector Replacement (See: Service and Repair) A/T Controls - Downshift Hesitation/Delayed Shifting Control Module: All Technical Service Bulletins A/T Controls - Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 7149 Important: Before removing the strut shaft nut, support the strut to prevent the strut from falling. 5. Remove the strut shaft nut, while holding the strut shaft. 6. Lower the strut from the spring and the J 45400. 7. Remove the upper strut mount assembly and mount bearing. Inspect for damage and replace as necessary. Page 10543 Page 10106 If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the Page 7048 of an ignition lock cylinder control actuator, and a park position switch that is located in the automatic transmission shift lock control switch. The ignition lock cylinder control actuator contains a pin that is spring loaded to mechanically prevent the ignition key cylinder from being turned to the lock position when the vehicle transmission is not in the PARK position. If vehicle power is lost, and/or the transmission is not in the PARK position the operator will not be able to turn the ignition key to the lock position and will not be able to remove the ignition key from the column. Linear Shift Assembly - If the vehicle is equipped with a column mounted gear shift, it has a linear shift assembly on the steering column. The linear shift assembly has a cable that runs from the linear shift assembly to the ignition lock cylinder case. The purpose of this cable is to prevent the ignition key from being turned to the OFF position when the transmission is in gear and the vehicle may still be moving. The linear shift assembly cable contains a pin that is spring loaded to mechanically prevent the ignition key cylinder from being turned to the lock position when the vehicle transmission is not in the PARK position. If vehicle power is lost, and/or the transmission is not in the PARK position the operator will not be able to turn the ignition key to the lock position and will not be able to remove the ignition key from the column. SIR Coil and Module - For additional information on the operation of the SIR coil and module, refer to SIR System Description and Operation (See: Restraint Systems/Air Bag Systems/Description and Operation/SIR System). Automatic Transmission Shift Lock Actuator - The automatic transmission shift lock control system is a safety device that prevents an inadvertent shift out of PARK when the engine is running. The driver must press the brake pedal before moving the shift lever out of the PARK position. The system consists of the following components: the automatic transmission shift lock control solenoid, the automatic transmission shift lock control switch, the body control module (BCM), the powertrain control module (PCM)/engine control module (ECM). With the ignition in the ON position, voltage is supplied to automatic transmission shift lock control switch. Voltage flows through the normally closed contacts of the automatic transmission shift lock control switch to the automatic transmission shift lock control solenoid. When the BCM receives a class 2 message from the PCM/ECM indicating the transmission is in the park position the BCM then grounds the automatic transmission shift lock solenoid control circuit. This energizes the automatic transmission shift lock control solenoid causing the transmission shift lever to be physically locked in the PARK position. When the brake pedal is pressed the contacts in the automatic transmission shift lock control switch open, de-energizing the automatic transmission shift lock control solenoid. This allows the shift lever to be move out of the PARK position. Steering Wheel Angle Sensor or Steering Wheel Position Sensor - The steering wheel position sensor is located somewhere along the steering shaft assembly. The sensor measures the position of the steering wheel and the speed at which it is rotated. A signal representing this measurement is provided to the vehicle stability enhancement system (VSES) module. The VSES module uses this signal, along with several others representing different vehicle conditions, to monitor the driving behavior of the vehicle and ensure that it stays in control. If the VSES module determines that the vehicle is out of control it provides signals to the powertrain control module (PCM) and the ABS module. These output signals are used to modulate the transmission torque and brake pressure of each of the vehicles wheels in order to regain control of the vehicle. 6T30/6T40/6T45 - Automatic Transmission Parking Pawl: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement Special Tools * DT-48550 Detent Lever Pin Remover * J 41229 Manual Shaft Pin Installer Removal Procedure 1. Remove the control valve body. 2. Remove the manual shaft detent lever hub pin (1) using DT-48550. 3. Remove the manual shift shaft pin (5). Discard the pin. 4. Remove the manual shaft (2). Note: Disconnect the actuator rod (3) from the detent lever assembly. Do not remove the actuator rod from the transmission case. 5. Remove the manual shaft detent (w/shift position switch) lever assembly (4). Installation Procedure Page 3736 Input Speed Sensor Seal Replacement Page 5667 Brake Booster Vacuum Sensor (LAT) Page 6525 X317 Inline Harness Connector End Views X317 DVD Signal Cable 3A to DVD Signal Cable 2A (SPO Accessory) (UJ5) Page 6455 Windshield Washer Fluid Level Switch Windshield Washer Fluid Pump Page 4131 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Electronic Components (MH8) Page 3438 12. Disconnect the fuel tank fuel feed pipe quick connect fitting (1) from the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 13. Disconnect the fuel tank EVAP pipe quick connect fitting (2) from the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 14. Cap the chassis fuel and EVAP pipes in order the prevent possible fuel and/or EVAP system contamination. 15. Remove the brake, fuel and EVAP pipe retainers (5) from the underbody studs. 16. Remove the brake pipes from the retainers. 17. Remove the fuel feed/EVAP pipe assembly from the vehicle. 18. Place the pipe assembly on a work bench. 19. Open and remove the upper fuel feed/EVAP pipe retainer (3). 20. Open and remove the front of dash fuel feed/EVAP pipe retainers (4). 21. Open and remove the underbody retainers (5). 22. Replace any retainers as necessary. Installation Procedure Page 398 1 - Inflatable Restraint Roof Rail Module - Right Front 2 - Inflatable Restraint Roof Rail Module Left Front 3 - Yaw and Lateral Accelerometer Sensor 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Page 3531 Ignition Coil 2 (LAT or LE5 or LE9) Page 876 Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 8. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. Page 10193 Oil Pressure Sender: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (LZ4 or LZE) Engine Oil Pressure (EOP) Switch (LAT or LE5 or LE9) Page 10807 Page 4184 Page 6183 Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 359 Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Locations Parking Brake Release Switch: Locations Instrument Panel/Center Console Component Views Lower Left Side of the Instrument Panel Components (2 of 2) 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ........................................ 345-414 kPa (50-60 psi). Verify the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute Page 9148 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Connector Position Assurance Locks Connector Position Assurance Locks Page 1476 Customer TPMS Information Page 10061 6. Release the rear lower half of the wire dress cover. 7. Release the tabs that are holding the wire dress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Page 4541 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Electronic Components (MH8) Locations Refrigerant Pressure Sensor / Switch: Locations Front of Vehicle/Engine Compartment Component Views Front and Right Rear of the Engine Compartment Components 1 - A/C Refrigerant Pressure Sensor 2 - Engine Cooling Fan - Right 3 - Engine Cooling Fan - Left 4 - Windshield Washer Fluid Pump 5 - Windshield Washer Fluid Level Switch 6 - Horn Assembly Diagrams Throttle Body: Diagrams Component Connector End Views Throttle Body Page 1813 Engine Block Heater: Service and Repair Coolant Heater Cord Replacement Coolant Heater Cord Replacement Removal Procedure 1. Remove the surge tank fasteners and reposition the tank aside. Refer to Radiator Surge Tank Replacement (See: Cooling System/Coolant Reservoir/Service and Repair/Radiator Surge Tank Replacement). 2. Disconnect the engine coolant heater cord (1). 3. Disconnect the clip (1) from the transmission range selector lever cable bracket (2). Page 3098 2. Measure from the same end as earlier, and slide the current sensor to that measurement on the negative battery cable. 3. Install the battery negative cable. Refer to Battery Negative Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). Page 3104 Camshaft Position (CMP) Sensor - Bank 2 Exhaust (LY7) Page 9194 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 4558 7. Remove the 2 control valve body bolts (4) M6 x 65. 8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95. 10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body and transmission control module (TCM) assembly (5). Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 12. Remove the control solenoid valve assembly filter plate (6). * Discard the filler plate. It is not reusable. * Inspect the pressure switch manifold seals for damage or contamination. Replace the control solenoid valve assembly as necessary. * Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage around the PCS seals. Replace the upper channel plate as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (1). Page 8187 Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Page 7051 Steering Wheel: Service and Repair Steering Wheel Shroud Replacement Steering Wheel Shroud Replacement Removal Procedure 1. Remove steering wheel. refer to Steering Wheel Replacement (See: Steering Column/Service and Repair/Steering Wheel Replacement) 2. Remove the steering wheel switch bezel bolts (2). Note: Note that the steering wheel switch bezel on the right side may be not contain a switch assembly on some models. Either style will be removed and installed the same way. 3. Unclip the steering wheel switch bezels (1). Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Page 1347 11. Perform the automated bleed procedure as instructed by the scan tool. 12. If the automated bleed procedure is aborted, a malfunction exists. If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) to diagnose the DTC. 13. After completion of the automated bleed procedure, press and hold the brake pedal to inspect for pedal firmness. 14. If the brake pedal feels spongy, repeat the bleed procedure completely. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 17. Lower the vehicle. 18. Adjust the brake fluid level. Refer to Master Cylinder Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 19. Road test the vehicle while confirming the brake pedal remains high and firm. Page 1975 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the engine oil pressure switch. Tighten the switch to 22 Nm (16 lb ft). 2. Connect the engine wiring harness electrical connector (2) to the oil pressure switch. 3. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). Page 10377 Page 3643 2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid valve spring (7) into position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Install all bolts before tightening, then tighten in specified sequence. 4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x 55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6 x 42. 8. Install the 2 control valve body bolts (4) M6 x 65 and tighten to 12 Nm (106 lb in). 9. Connect the input speed sensor electrical connector (1). 10. Connect the output speed sensor electrical connector (2). 11. Connect the shift position switch electrical connector (3). 12. Install the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Transmission and Drivetrain/Automatic Locations Heated Glass Element Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Antilock Brake System Automated Bleed Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Antilock Brake System Automated Bleed Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Note: * Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Hydraulic Brake System Bleeding). * The automated bleed procedure must be performed when a new brake pressure modulator valve (BPMV) is installed, because the secondary circuits of the new BPMV are not prefilled with brake fluid. * The automated bleed procedure is recommended when one of the following conditions exist: * Base brake system bleeding does not achieve the desired pedal height or feel * Extreme loss of brake fluid has occurred * Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out away from the brake modulator assembly, which is then forced out at the brake corners by the pressure bleeder. Automated Bleed Procedure Caution: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Repair or replace components as needed. 4. Lower the vehicle. 5. Prepare the brake bleeding equipment and the vehicle for a pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Hydraulic Brake System Bleeding). 6. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). 7. Install a scan tool. 8. Turn the ignition ON, with the engine OFF. 9. With the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Special Functions 6. Select Automated Bleed 10. With an assistant ready, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). Note: * Apply the brake pedal when instructed, using moderate effort. * Ensure the pedal remains applied until instructed to release by the scan tool. * Do not exceed the time period allowed by the scan tool for having the bleeder valves open. * The bleed sequence for each corner is as follows: - Left front - Right front - Right rear - Left rear Page 7181 6. Remove the wheel bearing/hub mounting bolts (1). 7. Remove the wheel bearing/hub and backing plate from the steering knuckle. Page 6852 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Page 6845 1 - Steering Wheel Position Sensor (NVH) Engine Controls - MIL ON/DTC P0172 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0172 Set TECHNICAL Bulletin No.: 10-06-04-004A Date: January 13, 2011 Subject: Intermittent Illumination of Malfunction Indicator Lamp (MIL)/Check Engine Light, DTC P0172 Set (Verify Alcohol Content Information in PCM) Models: 2010 Chevrolet Malibu Equipped with 2.4L 4 Cylinder Engine (VINs B, 0 - RPOs LE5, LE9) Please refer to GWM/IVH Supercede: This bulletin is being revised to update the engine type codes. Please discard Corporate Bulletin Number 10-06-04-004 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an intermittent illumination of the malfunction indicator lamp (MIL)/check engine light. Technicians may find a DTC P0172 set. Correction Use the procedure below to determine if the PCM has the incorrect alcohol content information. 1. Verify the actual measured percentage of alcohol content using the J-44175-A tester. Refer to Alcohol in Fuel Diagnosis in SI. If the actual alcohol is less than 15%, determine the "Fuel Alcohol Content" using the Tech 2(R). 2. Install the Tech 2(R) and build the vehicle as a 2010 and select Powertrain. 3. Build the vehicle with an LE9 engine (even if it has the LE5 engine). - Select Special Functions. - Select Fuel System (F2). Page 10040 Page 2474 Manifold Absolute Pressure (MAP) Sensor (LZ4 or LZE) Page 4275 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (ME7 or MN5) Procedures Brake Rotor/Disc: Procedures Brake Pad and Rotor Burnishing Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Brake Rotor Refinishing Brake Rotor Refinishing Special Tools * CH-41013 - Rotor Resurfacing Kit * CH-42450-A - Wheel Hub Resurfacing Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing. Do not refinish disc brake rotors in an attempt to correct the following conditions: - Brake system noise - squeal, growl, groan - Uneven and/or premature disc brake pad wear - Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface - Scoring of the disc brake rotor friction surface less than the maximum allowable specification * Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Refer to Brake Rotor Thickness Measurement (See: Testing and Inspection/Brake Rotor Thickness Measurement). Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: - Thickness variation in excess of the maximum allowable specification - Excessive corrosion/rust and/or pitting - Cracks and/or heat spots - Excessive blueing discoloration - Scoring of the disc brake rotor surface in excess of the maximum allowable specification * Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled lateral runout (LRO) that exceeds the maximum allowable specification. Note: If the vehicle is equipped with cross-drilled rotors, use a lathe with positive rake tooling. This setup requires less cutting pressure, which will result in less vibration, and a better surface finish. Also, use a vibration dampener when cutting. Otherwise, refinish according to the following instructions. Tires - Possible Wheel/Tire Vibration Tires: Technical Service Bulletins Tires - Possible Wheel/Tire Vibration ENGINEERING INFORMATION Bulletin No.: 09-03-10-009 Date: June 12, 2009 Subject: EI09137 - Possible Wheel/Tire Vibration on Vehicles Equipped with P225/50R18 Goodyear Tires (Engineering Information) Models: 2008-2010 Chevrolet Malibu 2008-2010 Pontiac G6 2008-2009 Saturn AURA Attention: Proceed with this bulletin ONLY if the customer has commented about this concern AND the EI number is listed in GMVIS. If the customer has not commented about this condition, or if the EI does not show in GMVIS, disregard this bulletin and proceed with diagnostics found in published service information. THIS IS NOT A RECALL. Refer to GM Corporate Service Bulletin 04-00-89-053B for more details on the use of Engineering Information bulletins. Condition Important Only vehicles equipped with 18" Goodyear Eagle LS2 P225/50R18 tires (TPC SPEC 1257 MS) are the subject of this bulletin. Some customers may comment on a tire or vehicle vibration. Cause GM Engineering is attempting to determine the root cause for a concern with vibrations in the vehicles identified above and equipped with Goodyear tires. GM has a need to obtain technical information from the dealer technician during diagnosis and PRIOR to repair. As a result, this information will be used by engineering to help root cause the customer's concern. Important If the customer vehicle has less than 800 km (500 mi) since delivery, the vibration may be caused by flat spots on the tires. While a vehicle sits in dealer inventory for extended periods, flat spots may develop on the tires that require extended driving to be eliminated. In many cases, the vibration will correct itself as the tire regains it's original round shape. Correction During diagnosis of the customer's concern, document the following information. 1. What is the customer's concern? Be specific. 2. When did the customer first notice the concern? 3. Under what conditions can the concern be duplicated? 4. Does the vehicle currently exhibit the condition? - If YES, go to Step 5 - If NO, no further repairs are possible at this time; do not proceed with this bulletin. 5. Complete the applicable sections of the Vibration Analysis Worksheet. Refer to Corporate Bulletin Number 03-00-91-001E. 6. Contact the engineer listed below and provide the data collected. Notice Following the recommendations in this bulletin does not override the GM guidelines for wheel balancing and alignments as described in Corporate Bulletin Number 01-03-10-012D. Contact Information For information and further instructions, please contact a GM engineer. Page 3216 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (ME7 or MN5) Page 9504 Page 9946 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Page 6467 Air Temperature Sensor - Upper (C68) Ambient Air Temperature Sensor Page 3122 Repair/Cooling System Draining and Filling). Page 3814 movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions See: Automatic Transmission/Transaxle/Description and Operation. Locations Pedal Positioning Sensor: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Lower Left Side of the Instrument Panel Components (1 of 2) Page 4729 7. Remove the wheel nuts retaining the brake rotor to the wheel hub. 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10 and 11 until a firm brake pedal is obtained. This will properly seat the brake caliper piston and brake pads. Rear Brake Caliper Replacement Rear Brake Caliper Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 6. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad. Caution: When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 in) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism. 7. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. Do not exceed 1 mm (0.039 in) of caliper piston travel. 8. Remove the C-clamp from the caliper. Page 3679 Control Module: Service and Repair Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover Replacement). 2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3). 5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring (8) to the side. Spring will be released with the removal of the control valve body assembly. 7. Remove the 2 control valve body bolts (4) M6 x 65. Page 4466 Page 3285 Page 5878 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 180 Page 7542 15. Install the liquid line and compressor hose bolt to the condenser and tighten to 20 Nm (15 lb ft). Note: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur. 16. Install the left radiator air deflector. 17. Install the left radiator air deflector retainers. Page 7862 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 8288 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. Locations Sunroof / Moonroof Switch: Locations Passenger Compartment/Roof Component Views Roof/Headliner and Overhead Console Components 1 - Dome/Reading Lamps 2 - Center Console Flood Lamp 3 - Sunshade - Right 4 - Vanity Mirror Lamp - Right (2TL or LTZ) (Part of Sunshade - Right) 5 - Garage Door Opener (GDO) (UG1) 6 Courtesy/Reading Lamps - Right Front 7 - Sunroof Switch (CF5) 8 - Courtesy/Reading Lamps Left Front 9 - Vanity Mirror Lamp - Left (2TL or LTZ) (Part of Sunshade - Left) 10 - Sunshade - Left 11 - Cellular Telephone Microphone (UE1) Page 4325 25. Install the battery tray assembly. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair). 26. Fill the transmission. Refer to Approximate Fluid Capacities (See: Maintenance/Specifications). Control Valve Body Cover Gasket Replacement Control Valve Body Cover Gasket Replacement Removal Procedure 1. Remove the transmission side cover. Refer to Control Valve Body Cover Replacement (See: Control Valve Body Cover Replacement). 2. Remove the side cover gaskets (5 and 6) and the thrust washer (7) from the side cover (1). 3. Inspect the side cover for cracks or damage to the seal grooves and mounting bosses. 4. Inspect the side cover seals for damage. The side cover seals are reusable if not damaged. 5. Thoroughly clean the side cover and the side cover seals. Clean and dry the seal grooves and the axle seal bore. Installation Procedure Page 685 For vehicles repaired under warranty use the table above. Disclaimer Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Page 6449 Window Motor - Left Rear Window Motor - Passenger Page 10592 Window Switch - Right Rear Page 5895 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 9118 Locations Refrigerant Pressure Sensor / Switch: Locations Front of Vehicle/Engine Compartment Component Views Front and Right Rear of the Engine Compartment Components 1 - A/C Refrigerant Pressure Sensor 2 - Engine Cooling Fan - Right 3 - Engine Cooling Fan - Left 4 - Windshield Washer Fluid Pump 5 - Windshield Washer Fluid Level Switch 6 - Horn Assembly Page 1631 Disclaimer Page 10102 within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) Page 7485 Auxiliary Water Pump: Service and Repair Heater Coolant Pump Replacement Page 5739 Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 8235 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Connector Position Assurance Locks Connector Position Assurance Locks Page 3695 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transaxle case side cover. 2. Remove the TFP switch assembly bolts. 3. Remove the TFP switch assembly from the control valve body assembly. The TFP switch O-rings are reusable if not damaged and should remain with the switch assembly. Installation Procedure 1. Inspect the TFP switch assembly in order to verify the condition and correct location of the pressure switch O-rings. If necessary, replace the O-rings. Caution: Refer to Fastener Caution Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Page 6292 Engine Oil Pressure (EOP) Switch (LY7) Evaporative Emission (EVAP) Canister Purge Solenoid Valve (LAT or LE5 or LE9) Page 4059 4. Remove the output axle seal. 5. Use the J 41227 to remove the sleeve from the output axle. Installation Procedure Important: * The stub axle shaft sleeve and seal must be replaced together. DO NOT replace the sleeve or seal separately. * Do not damage the seal bore or the sleeve assembly. Fluid leaks may result. Specifications Compression Check: Specifications Engine Compression Test The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Front Side Door Emblem/Nameplate Replacement Body Emblem: Service and Repair Front Side Door Emblem/Nameplate Replacement Front Side Door Emblem/Nameplate Replacement Locations Power Distribution Module: Locations Luggage Compartment/Rear of Vehicle Component Views Rear Window Shelf Components 1 - Cellular (UE1) and Digital Radio Antenna (U2K) 2 - Radio Antenna Module 3 - Remote Start Antenna (AP3) 4 - Speaker - Right Rear 5 - Accessory AC/DC Power Control Module (KV1) 6 Audio Amplifier (UQ3) 7 - Rear Compartment Courtesy Lamp 8 - Remote Control Door Lock Receiver (RCDLR) 9 - Digital Radio Receiver (U2K) 10 - Speaker - Left Rear Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Page 3758 - Select Fuel Composition Reset (F1). - The first parameter is "Fuel Alcohol Content" displayed as a percentage. If the Fuel Alcohol Content percentage is above 25%, this is the probable cause of DTC P0172. - From this screen the "Fuel Alcohol Content" can be reset to zero by pressing the lower right Tech 2(R) button. It will then display 0% when it's reset. Finally, reprogram the PCM with the latest calibration. This will correct for the PCM alcohol calculations. Note The PCM must be reset from this screen. It does not reset to zero when the PCM is reprogrammed. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7173 Second Design - Black Painted (DO NOT Lube) Hydraulic Assist Power Steering First Design - Bare Steel Tube (Lube OK) Second Design - Black Painted (DO NOT Lube) In the unlikely event that the source of the noise is identified as a second design shaft with black painted tube, it must be replaced. Correction 1 (Only for First Design - DO NOT USE FOR 2ND DESIGN) Lubricate the intermediate shaft with steering column shaft lubrication kit, P/N 26098237. 1. From inside the vehicle, remove the instrument panel insulator panel - left side panel to gain access to the intermediate shaft. 2. Remove the intermediate shaft to steering column attachment bolt. 3. Remove the intermediate shaft from the steering column. 4. Extend the intermediate shaft all the way. Using the intermediate shaft grease kit, P/N 26098237, inject the grease into the gap between the inner shaft and the outer shaft as you are collapsing the shaft. This will draw the grease into the shaft. 5. Cycle the shaft up and down several times to distribute the grease. Important Remove original thread locker material from the bolt and apply Loctite(R) 242 (or equivalent) to the threads of the bolt and reinstall intermediate shaft bolt. 6. Install the intermediate shaft to the column. Tighten - For electronic power steering, tighten the bolt to 49 Nm (36 lb ft). - For hydraulic power steering, tighten the bolt to 62 Nm (46 lb ft). Page 2868 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5136 Page 8982 Console: Service and Repair Front Floor Console Accessory Trim Plate Replacement Front Floor Console Accessory Trim Plate Replacement Front Floor Console Extension Panel Replacement - Left Side Front Floor Console Extension Panel Replacement - Left Side Page 8234 6. Release the rear lower half of the wire dress cover. 7. Release the tabs that are holding the wire dress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Page 7981 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. 2008 Model Year Buick Enclave, GMC Acadia and Saturn OUTLOOK Vehicles Only Note The seat mounted side impact airbag connection to the body harness is located at the forward edge of the seat, below the plastic trim. The connectors are yellow. The body harness wires are exposed - running forward in the vehicle, down through the carpet cutout in the floor. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 5779 Fuse Block - Underhood X2 Page 3655 Transmission Mode Indicator - A/T: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Automatic Transmission Control Indicator Replacement Page 9399 Power Seat Motor: Diagrams Component Connector End Views Seat Front Vertical Motor - Driver Seat Front Vertical Motor - Passenger Page 6086 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Power Outlet Schematics I/P and Center Console Outlet 110V AC Outlet (KV1) Page 6308 Generator X1 (LY7) Generator X1 (LZ4 or LZE) Page 6138 FUSE PULLER .................................................................................................................................... ............................................................ Fuse Puller Page 9143 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Page 10162 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Page 8329 Central Control Module: Diagrams Component Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Page 1606 6. Position the wheel and tire so the valve stem is again at the 7 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM, replace the tire pressure sensor. Refer to Tire Pressure Indicator Sensor Replacement (See: Sensors and Switches - Wheels and Tires/Tire Pressure Sensor/Service and Repair). 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Caution: When mounting the tires, use an approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A silicon base compound can cause the tire to slip on the rim. A corrosive type compound can cause tire or rim deterioration. 9. Apply mounting lubricant to the tire bead and the wheel rim. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications/Suspension). 10. Position the rim so the valve stem (1) is at the 7 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. Page 2760 Engine Control Module (ECM) X2 (LE5 or LE9) Page 1355 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Page 9195 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Page 6434 Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve (ME7 or MN5) Page 7577 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Page 6427 Sunshade - Left (LTZ) Page 1918 Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 5215 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 4458 Page 4484 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH8) Page 5665 Body Control Module (BCM) X4 Page 8891 Body Emblem: Service and Repair Front Fender Emblem/Nameplate Replacement Front Fender Emblem/Nameplate Replacement Page 2025 Variable Valve Timing Solenoid: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (1) from the exhaust camshaft position (CMP) actuator solenoid valve (4), if required. 3. Disconnect the engine wiring harness electrical connector (2) from the intake CMP actuator solenoid valve (3), if required. 4. Remove the exhaust (1) CMP actuator solenoid valve bolt and valve, if required. 5. Remove the intake (2) CMP actuator solenoid valve bolt and valve, if required. 6. Inspect the solenoid valve O-ring seals for damage, replace as necessary. Installation Procedure Page 10283 Courtesy Lamp - Right Front Door Rear Compartment Courtesy Lamp Diagrams Air Injection Pump Relay: Diagrams Component Connector End Views Secondary Air Injection (AIR) Pump Relay (NU6) Page 509 For vehicles repaired under warranty use the table above. Disclaimer Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (except LAT) Page 3675 Transmission Control Module (TCM) (MN5 with LE5 or LE9) Page 6542 X701 Inline Harness Connector End Views X701 Left Rear Door Harness to Left Rear Door Trim Pad Harness Page 8512 Speaker - Right Front (UQA) Speaker - Right Front (UQ3) Page 169 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Page 4262 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the left tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Using a suitable jack stand, support the rear of the powertrain. 4. Remove the transmission mount to bracket through bolt (1). 5. Remove the transaxle brace bolts (1), then loosen bolt (3) until it no longer engages the transaxle. 6. Remove the transaxle brace (2) with bolt (3) still retained in the brace. Page 7476 Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Right Side Instrument Panel Outer Air Outlet Replacement - Right Side Page 2675 Camshaft Position (CMP) Sensor - Exhaust (LAT or LE5 or LE9) Page 9624 Page 3153 Knock Sensor: Service and Repair Knock Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (1) from the knock sensor pigtail electrical connector (6). 4. Remove the knock sensor electrical connector pigtail (6) clip from the oil level indicator tube bracket. 5. Remove the knock sensor bolt. 6. Remove the knock sensor. Installation Procedure Page 314 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 1388 Body Control Module (BCM) X1 Page 4198 Shift Cable: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Automatic Transmission Range Selector Lever Replacement Automatic Transmission Range Selector Lever Replacement Removal Procedure 1. Set the park brake and chock the wheels. 2. Disconnect the transmission range selector lever cable terminal (1) from the transmission manual shift lever pin. 3. Press the locking tabs inward in order to release the transmission range selector lever cable (2) from the cable bracket. Warning Front Side Door Bottom Auxiliary Sealing Strip Replacement Front Door Weatherstrip: Service and Repair Front Side Door Bottom Auxiliary Sealing Strip Replacement Front Side Door Bottom Auxiliary Sealing Strip Replacement Page 3518 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Exhaust Camshaft Position Sensor Replacement - Exhaust Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (5) from the exhaust camshaft position (CMP) sensor (4). 3. Remove the CMP sensor bolt. (Intake CMP shown, exhaust CMP similar). 4. Remove the CMP sensor. Installation Procedure Page 358 Page 6291 Engine Cooling Fan - Right Engine Oil Pressure (EOP) Sensor (LZ4 or LZE) Engine Oil Pressure (EOP) Switch (LAT or LE5 or LE9) Page 1052 Input Speed Sensor Seal Replacement Campaign - Airbag Readiness Light/Service Airbag Message Technical Service Bulletin # 10085D Date: 110203 Campaign - Airbag Readiness Light/Service Airbag Message CUSTOMER SATISFACTION Bulletin No.: 10085D Date: February 03, 2011 Subject: 10085D - Airbag Readiness Light/Service Airbag Message - Replace Connectors Models: 2008 Buick Enclave 2010 Chevrolet Malibu 2008 GMC Acadia 2010 Pontiac G6 2008 Saturn OUTLOOK Supercede: The Service Procedure in this bulletin has been revised. All vehicles will not require the replacement of the front seat-mounted side impact airbag connectors.Please discard all copies of bulletin 10085C, issued November 2010. Condition Certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may experience wear which could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact air bag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG System warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG System DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Correction Dealers are to replace the front seat-mounted side impact airbag connectors. Vehicles Involved Involved are certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Part Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your Page 6997 8. Install the three pieces of foam to the attaching bracket starting at the top center inside the bracket and proceed down across the fuel lines, then at the inside of the bracket at the left and right positions of the center piece of foam. Finally, install the last two pieces of foam to the inside bracket at the left and right extended sides behind the retaining holes as shown above. 9. Reposition the radiator surge tank back onto the bracket and seat the two retaining tabs on the tank. 10. Drive the vehicle to verify that the noise is no longer present. Parts Information Order Adhesive Back Shim Stock from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 4513 1. Install the 3 input speed sensor seals (1). 2. Install the input speed sensor (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the input speed sensor bolt (2) M6 x 23 and tighten to 12 Nm (106 lb in). 4. Connect the input speed sensor electrical connector (1). 5. Install the transmission control valve body cover. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning/6T30/6T40/6T45 - Automatic Transmission). Component Locations Canister Vent Valve: Component Locations Wheels/Vehicle Underbody Component Views Fuel Tank Components 1 - Evaporative Emission (EVAP) Canister 2 - Evaporative Emission (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly 4 - Fuel Tank Pressure (FTP) Sensor 5 - Fuel Tank Page 1323 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 6264 Electronic Brake Control Module (EBCM) (LE5 or LE9) Page 3439 1. Install and close the underbody retainers (5). 2. Install and close the front of dash fuel feed/EVAP pipe retainers (4). 3. Install and close the upper fuel feed/EVAP pipe retainer (3). 4. Position the fuel feed/EVAP pipe assembly to the vehicle. 5. Install the brake pipes to the retainers. 6. Install the brake, fuel and EVAP pipe retainers (5) to the underbody studs. 7. Remove the caps from the chassis fuel and EVAP pipes. 8. Connect the fuel tank EVAP pipe quick connect fitting (2) to the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 9. Connect the fuel tank fuel feed pipe quick connect fitting (1) to the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Page 6532 X407 Inline Harness Connector End Views X407 Body Harness to Generator Battery Assembly Harness (HP7) X411 Inline Harness Connector End Views X411 Body Harness to the Left Roof Rail Jumper Harness Page 2703 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Auxiliary Power Outlet: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Special Tools J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. The J 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. Page 574 Brake Booster Vacuum Sensor: Service and Repair Power Brake Booster Vacuum Sensor Replacement Page 4065 7. Install two NEW snap rings on the stub shaft. 8. Apply grease to the output shaft splines. Note: J 41102-1A must be used in order to install the axle seal to the correct depth. 9. Install a NEW seal (1). Use the J 41102-1A (3) with J 8092 (2). Lubricate the seal lip with transmission fluid. Fuel Pressure Gauge Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gauge Installation and Removal Fuel Pressure Gauge Installation and Removal Special Tools CH-48027-100 - Digital Pressure Gauge For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Connect the CH-48027-1 - gauge (1) to the CH-48027-2 - adapter (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027-100 - gauge, refer to the manufacture's directions. Removal Procedure Page 9709 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Locations Camshaft Position Sensor: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch Page 7920 Ensure that the appropriate wire colors match up (as noted in Step 4) when the connection is made between the seat airbag harness and body harness. 10. Slide all four terminals (2) into the appropriate connector body as shown above. Install the blue terminal position assurance (TPA) devices onto the connector ends. 11. Add NyoGel 760 Lubricant (dielectric lubricant), P/N 12377900 (in Canada, use P/N 10953529) (Saturn retailers, use P/N 12345579) to the terminals on both sides of the connections. 12. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the body harness up to the back of the connector. 13. Reinstall the conduit on the seat airbag harness. 14. Repeat the above procedure on the passenger seat. Reinstall Seats 1. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 2. Reconnect the seat to body harness connector and the seat airbag connector. Reroute Harness and Secure Connector Follow the procedure below to re-route and attach the harness connector to the body harness bundle: 1. The original seat airbag connector was attached with a clip to the bottom of the seat (2) as shown above. 2. Using two wire ties, secure the seat airbag connector to the seat wire bundle as shown. Ensure that there is enough slack for full range of motion of the seat. 3. Inspect the wires through the full range of motion of the seat again as in Step 2. Ensure that the wires have been secured in an orientation that allows full seat motion with adequate clearance to the connectors and sufficient slack in the wires. 4. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 5. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Page 3572 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (7) to the intake CMP sensor (6). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 7817 Disclaimer Service Procedure Service Procedure Air Bag Connector Inspection 1. Move the driver's seat to the maximum forward position and raise the seat to its maximum height. 2. Using a flash light, locate the air bag and body wire harnesses. Note Vehicles that have new air bag connectors will have a tie strap securing the two (2) wires exiting the air bag connector to the main body wiring harness. In addition, the new air bag connectors will have an orange connector position assurance (CPA) clip that is tethered to the connector. Ensure both the orange CPA clip and tie strap are located. Air bag and body wire harnesses without the tie strap and/or CPA clip must have the air bag connectors replaced. 3. Determine if the new air bag connectors have been installed. - If the vehicle is equipped with the new air bag connectors, no further action is required. Refer to Warranty Transaction Information in this bulletin. - If the vehicle is NOT equipped with the new air bag connectors, replace the air bag connectors. Refer to Replace Wire Harness Connector in this bulletin. Replace Wire Harness Connector Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. (Seat shown out-of-vehicles for illustration purposes) Page 4502 1 - Control Valve Body Cover Bolt 2 - Control Valve Body Cover Assembly 3 - Control Valve Body Cover Gasket 4 - Control Valve Body Bolt 5 - Control Valve Body Cover Hole Seal 6 - Control Solenoid Valve Heat Sink Bolt 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Control Valve Body Filter Plate Assembly 9 - Control Valve Body Bolt 10 - Control Valve Body Bolt 11 Control Valve Body Assembly 12 - Control Valve Body Spacer Plate Assembly 13 - A/Trans Fluid Level Control Valve 14 - A/Trans Fluid Level Control Valve Gasket 15 - A/Trans Output Speed Sensor Bolt 16 - A/Trans Output Speed Sensor Assembly 17 - Manual Shaft Detent Spring Bolt 18 - Manual Shaft Detent Lever Spring Assembly 19 - A/Trans Input Speed Sensor Assembly 20 A/Trans Input Speed Sensor Assembly O-Ring Seal 21 - A/Trans Input Speed Sensor Bolt 22 - Fill Cap 23 - Fill Cap Seal 24 - Torque Converter Housing Gasket Page 1702 Wheel Bearing: Service and Repair Rear Suspension Rear Wheel Bearing and Hub Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 4. Disconnect the electrical connector from the wheel speed sensor. 5. Remove the 4 wheel bearing/hub assembly nuts. 6. Remove the wheel bearing/hub assembly from the knuckle. Installation Procedure Page 568 Trunk / Liftgate Switch: Service and Repair Rear Compartment Lid Release Switch Replacement Page 6808 Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Page 10083 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 1076 Washer Fluid Level Switch: Diagrams Component Connector End Views Windshield Washer Fluid Level Switch Tire Pressure Monitor - TPM System Message/Service Tips Tires: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 4759 11. Remove the brake pad retainers (2) from the caliper bracket (1). 12. Thoroughly clean the brake pad hardware mating surfaces of the caliper bracket (1), of any debris and corrosion. 13. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: * Restricted caliper guide pin movement * Looseness in the brake caliper mounting bracket * Seized or binding caliper guide pins * Split or torn boots 14. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Installation Procedure 1. Ensure the brake pad hardware mating surfaces (1) are clean. 2. Install the brake pad retainers (2) to the brake caliper bracket. Page 3146 1. Install the MAF/IAT sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1) and tighten to 2.5 Nm (22 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor (2). Locations Torque Converter Clutch Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 2923 ‹› If greater than the specified range, test the serial data circuit for a short to voltage, refer to Testing the Serial Data Circuit for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuit terminal 1 and ground. ‹› If less than the specified range, test the serial data circuit for a short to ground, refer to Testing the Serial Data Circuits for a Short to ground. 6. Disconnect the appropriate harness connector at the BCM. 7. Test for less than 2 ohm between the DLC serial data circuit terminal 1 and the BCM connector. ‹› If greater than the specified range, test the serial data circuit for an open/high resistance. If the circuits test normal, replace the BCM. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the appropriate harness connectors at the BCM. 2. Ignition ON, test for less than 4.5 V between the DLC serial data circuit terminal 1 and ground. ‹› If greater than the specified range, repair the short to voltage. 3. Test for less than 4.5 V between each serial data circuit at the BCM connectors and ground. ‹› If greater than the specified range, perform the appropriate test listed below: * Serial data circuits with one control module, test the serial data circuit for a short to voltage. If the circuit tests normal replace the control module. * Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a short to voltage. If the circuits test normal, replace the control module that causes the short to voltage when connected. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the appropriate harness connectors at the BCM. 2. Test for infinite resistance between the DLC serial data circuit terminal 1 and ground. ‹› If not the specified value, repair the short to ground. 3. Ignition OFF for 60 seconds, test for greater than 100 ohm between each serial data circuit and ground. ‹› If less than the specified range, perform the appropriate test listed below: * Serial data circuits with one control module, test the serial data circuit for a short to ground. If the circuit tests normal replace the control module. * Serial data circuits with 2 or more control modules, test each section of the serial data circuit for a short to ground. If the circuits test normal, replace the control module that causes the short to ground when connected. Testing the Serial Data Circuit for an Open/High Resistance 1. Ignition OFF, disconnect the appropriate harness connectors at the BCM. 2. Install a 3 A fused jumper wire between the disconnected BCM connector DLC terminal and a low speed GMLAN serial data circuit terminal that is not communicating. 3. Ignition ON, verify the scan tool communicates with the control modules connected to the low speed GMLAN serial data circuit. ‹› If any control module does not communicate, test each section of the serial data circuit for an open/high resistance. If the circuits test normal, replace the control module that does not communicate when connected. Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * Control Module References (See: Testing and Inspection/Programming and Relearning) for module replacement, setup, and programming Scan Tool Does Not Power Up Scan Tool Does Not Power Up Page 4715 corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm which may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system; begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (See: Hydraulic Brake System Bleeding). Page 7641 Heater Core: Service and Repair Heater Core Replacement Heater Core Replacement Removal Procedure 1. Remove the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Housing Assembly HVAC/Service and Repair). 2. Remove the center floor air outlet duct screws. 3. Remove the center floor air outlet duct. 4. Drill out the heater core cover heat stakes. 5. Remove the heater core cover screws. 6. Remove the heater core cover. Page 3430 11. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors. 12. Remove the fuel injector wiring harness clips from the fuel rail. 13. Remove the fuel injector wiring harness from the fuel rail. 14. Remove the fuel injectors, if necessary. Refer to Fuel Injector Replacement (See: Fuel Injector/Service and Repair). Installation Procedure Note: Install only NEW lower O-rings if the fuel rail and injectors were removed and re-installed. If the fuel rail was replaced, then install NEW upper and lower O-rings. 1. Install the fuel injectors, if necessary. Refer to Fuel Injector Replacement (See: Fuel Injector/Service and Repair). 2. Install the fuel injector wiring harness clips to the fuel rail. 3. Connect the fuel injector wiring harness electrical connectors to the fuel injectors. Page 4771 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Page 6466 Air Temperature Actuator Air Temperature Sensor - Lower (C68) Page 9864 Page 4488 Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 4. Remove the transaxle range switch lever nut and lever. 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. Page 9842 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement Front Door Opening Weatherstrip Replacement Page 5543 Manifold Absolute Pressure (MAP) Sensor (LZ4 or LZE) Page 1465 Page 6373 Side Marker Lamp - Left Front Specifications Water Pump: Specifications Water Pump Bolts ................................................................................................................................ ........................................................ 25 Nm (18 lb ft) Page 4556 movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions See: Automatic Transmission/Transaxle/Description and Operation. Page 9474 Page 6082 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Page 2456 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 5012 Wheel Speed Sensor (WSS) - Right Front Wheel Speed Sensor (WSS) - Right Rear Page 1920 Engine Oil Pressure (EOP) Switch (LY7) Page 6514 X208 Inline Harness Connector End Views X208 I/P Harness to Body Harness Page 7236 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Testing and Inspection). Page 5693 X315 Inline Harness Connector End Views X315 DVD Signal Cable 3A to DVD Signal Cable 1A (SPO Accessory) (UJ5) Locations Brake Booster Vacuum Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Page 10007 Page 10589 Power Window Switch: Diagrams Component Connector End Views Window Switch - Driver X1 Window Switch - Driver X2 Page 1217 1. Install the NEW oil filter to the cap. 2. Install the oil filter cap and filter. Caution: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. Note: DO NOT use an open end wrench on the hex on top of the oil filter cap. 3. use an oil filter wrench on the outside diameter of the oil filter cap. Tighten the oil filter cap until fully seated. DO NOT exceed 25 Nm (18 lb ft). 4. Fill the engine with oil. Refer to Fluid and Lubricant Recommendations (See: Maintenance). Page 9642 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Page 5404 Center High Mounted Stop Lamp (CHMSL) Control Solenoid Valve Assembly (MH2) Page 5239 GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The Page 5712 X700 Inline Harness Connector End Views X700 Body Harness to Left Rear Door Harness Page 5791 Page 10244 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Page 10425 Page 6437 Transmission Control Module (TCM) (MN5 with LE5 or LE9) Page 8245 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Page 7565 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 827 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 4234 Disclaimer Page 7433 Temperature Valve Actuator Replacement Temperature Valve Actuator Replacement Page 4243 Transmission Mode Switch: Service and Repair Manual Shift Auxiliary Position Switch Replacement - Steering Wheel Page 5179 Auxiliary Power Outlet: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 1478 Frequently Asked Questions Disclaimer Page 5413 Digital Video Disc (DVD) Control Module X2 (SPO Accessory) (UJ5) Page 2021 Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust (LY7) Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake (LY7) Page 9614 Page 1711 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: * The wheel/nut has the word Metric stamped on the face. * The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. * M = Metric * 12 = Diameter in millimeters * 1.5 = Millimeters gap per thread Page 9707 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the MYLAR tape. If the MYLAR tape is damaged, use 3M product AL-36FR to replace the damaged MYLAR tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Rear Side Door Outside Handle Housing Replacement Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Housing Replacement Rear Side Door Outside Handle Housing Replacement Page 7077 4. Using the appropriate tool, remove the park brake cable retaining clip (2) from the trailing arm bracket (1). 5. Remove the trailing arm bracket mounting bolts. 6. Remove the bolts (1) from the trailing arm to the knuckle. Page 1896 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Page 8130 Antenna, Phone: Service and Repair Mobile Telephone and Vehicle Location Antenna Base Replacement Mobile Telephone and Vehicle Location Antenna Base Replacement Page 7040 8. Install the three pieces of foam to the attaching bracket starting at the top center inside the bracket and proceed down across the fuel lines, then at the inside of the bracket at the left and right positions of the center piece of foam. Finally, install the last two pieces of foam to the inside bracket at the left and right extended sides behind the retaining holes as shown above. 9. Reposition the radiator surge tank back onto the bracket and seat the two retaining tabs on the tank. 10. Drive the vehicle to verify that the noise is no longer present. Parts Information Order Adhesive Back Shim Stock from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 8484 Amplifier: Service and Repair Radio Speaker Amplifier Replacement Page 3926 Note: Do not score or damage the transaxle case when removing the filter neck seal. 12. Using a chisel, indent the top of the filter neck seal to relax the press fit. 13. Remove the filter neck seal from the transaxle case and discard. 14. Remove all traces of the old gasket material. 15. Clean the transaxle case and oil pan gasket surfaces with solvent, and allow to air dry. Installation Procedure Caution: Use petroleum jelly when lubricating the components. Greases other than petroleum jelly will change the transaxle fluid characteristics and will cause undesirable shift conditions or filter clogging. 1. Install a new filter neck seal. A large socket can be used as an installation tool as shown. Two mallets can be used as well. Page 4468 Page 1989 10. Remove the timing chain tensioner guide bolt and guide. 11. Remove the fixed timing chain guide access plug. Page 1848 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 5142 Page 12 Antenna Control Module: Diagrams Component Connector End Views Radio Antenna Module Page 4807 Special Tools * J 41013 Rotor Resurfacing Kit * J 42450-A Wheel Hub Resurfacing Kit Removal Procedure 1. Check to be sure that the park brake is released. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Note: Do NOT disconnect the hydraulic brake flexible hose from the caliper. 4. Remove the brake caliper mounting bracket and caliper as an assembly from the suspension knuckle and support the assembly with heavy mechanic's wire, or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose. Refer to Rear Brake Caliper Bracket Replacement (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement). 5. Matchmarks the position of the brake rotor to the wheel studs. 6. Remove the brake rotor. Do not force the rotor off. If the rotor is difficult to remove, ease it off by gently rotating it as you pull outward. Installation Procedure Note: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 1. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J 41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. Page 5230 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Front and Right Side of the Engine Components (LY7) Page 4356 Providing responsible services at the proper intervals will greatly aid your dealership with repeat business, and additional services when required. Most customers appreciate and gain trust in the dealership that informs and offers them just what they need for continued trouble-free operation. Examine your service department's practices and verify that all Service Consultants and Technicians focus on customer satisfaction, vehicle inspections, and other products at time of service. Use this opportunity to upgrade the services you provide to your customers. Here are a few suggestions: - Take the time required to align your dealership service practices with the new GM Simplified Maintenance Schedule. Use the new vehicle Owner's Manual Maintenance I and II schedules to create a "mirror image" in your advertising and dealer service pricing that is easily understandable to your customer. Taking advantage of this new service strategy may greatly increase your dealership service sales and customer retention while decreasing the frequency of visits and inconvenience to your customer. - Review your program to ensure that all vehicles coming in are evaluated for safety and wear items. Examine all vehicles for tire condition, signs of misalignment, brake wear, exterior lamp functionality, exhaust condition, A/C cooling performance, SRS or Air Bag MIL, along with Service Engine Soon or Check Engine indicators. If the Service Engine Soon or Check Engine MIL is illuminated, it is vital that you inform the customer of the concerns with ignoring the indicator and what the required repair would cost. In addition to the possibility of increased emissions and driveability concerns, many customers are unaware that lower gas mileage may also result, with additional cost to the customer. - Be complete in your service recommendations. Some sales opportunities are not being fully pursued nationally. Focus on overlooked but required maintenance that has real benefits to the customer. Many vehicles are equipped with cabin air filters. If these filters are used beyond replacement time, they may impede airflow decreasing A/C and heating performance. Make sure these filters are part of your recommended service. Note that some of our vehicles may not have been factory equipped but will accept the filters as an accessory. - Express the value in maintaining the finish quality of the customer's vehicle at the Maintenance I and II visits. More fully utilize the vehicle prep personnel you already have in place. In today's world, many people simply ignore the finish of their vehicle, at best infrequently using an automatic car wash for exterior cleaning. Offer vehicle detailing services in stages from just a wash and wax to a complete interior cleaning. When paired with the Simplified Maintenance visit, this will increase customer satisfaction. On return, the customer gets a visibly improved vehicle that will be a source of pride of ownership along with a vehicle that is now fully maintained. Also, reinforce the improved resale value of a completely maintained vehicle. - For customers who clean and maintain the appearance of their vehicles themselves encourage the use of GM Vehicle Care products. Many customers may have never used GM Car Wash/Wax Concentrate, GM Cleaner Wax or a longtime product, GM Glass Cleaner, which is a favorite of many customers who try it just once. If your dealership give samples of these products with new car purchases, customers may already be sold on the product but not willing to make a special trip to the dealership. Capitalize on sales at this time. Stock shelves right at the Service counter with these products and consider instituting compensation programs for Service Consultants who suggest these products. Many consumers faced with an intimidating wall full of car care products sold at local auto parts stores may find it comforting to purchase a fully tested product sold by GM that they know will not harm the finish of their vehicle. We suggest these competitively priced basic vehicle care products to emphasize: In USA: - #12378401 GM Vehicle Care Wash/Wax Concentrate 16 fl. oz. (0.473L) - #89021822 GM Vehicle Care Glass Cleaner Aerosol 18 oz. (510 g) - #12377966 GM Vehicle Care Cleaner Wax 16 fl. oz. (0.473L) - #1052929 GM Vehicle Care Chrome and Wire Wheel Cleaner 16 fl. oz. (0.473L) - #88861431 GM Vehicle Care Odor Eliminator 24 fl. oz. (0.710L) In Canada: - #10953203 GM Vehicle Care Wash & Wax Concentrate 473 mL - #992727 GM Glass Cleaner Aerosol 500 g - #10952905 GM Vehicle Care Liquid Cleaner/Wax 473 mL - #10953013 GM Vehicle Care Chrome Cleaner and Polish 454 mL - #10953202 GM Vehicle Care Wheel Brite 473 mL - #88901678 GM Vehicle Care Odor Eliminator 473 mL - Display signboards with the installed price for popular GM Accessories such as running boards and Tonneau Covers. Customers may not think to ask about these desirable items at the time of a service visit. - Finally, take advantage of the GM Goodwrench initiatives (Tire Program, Goodwrench Credit Card, etc. / Dealer Marketing Association (DMA) Promotions in Canada) to provide the customer with more reasons to identify your dealership as the best place to go for parts and service. Remember to utilize ALL of the service aspects you possess in your dealership to satisfy and provide value to your customer. Many businesses exist profitably as an oil change location, a vehicle repair facility, or a detailing shop alone. You already have the capabilities of all three and provide these services with the inherent trust of your customer, under the GM Mark of Excellence. Disclaimer Page 5398 Camshaft Position (CMP) Sensor - Bank 1 Intake (LY7) Page 9544 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Testing and Inspection Transmission Mount: Testing and Inspection Transmission Mount Inspection Caution: In order to avoid oil pan damage and possible engine failure, insert a block of wood that spans the width of the oil pan bottom between the oil pan and the jack support. 1. Raise and support the vehicle. 2. Place a jackstand under the transmission/transaxle. 3. Place a block of wood between the jack stand and the transaxle in order to protect the transmission/transaxle pan. Note: Before replacing any transmission/transaxle mount due to suspected fluid loss, verify that the source of the fluid is the transmission/transaxle mount, not the engine, transmission/transaxle or accessories. 4. Raise the transmission/transaxle in order to remove the weight from the transmission/transaxle mount and create slight tension in the rubber. 5. Observe the transmission/transaxle mount while raising the transmission/transaxle. Replace the transmission/transaxle mount if the transmission/transaxle mount exhibits any of the following conditions: * The hard rubber surface is covered with heat check cracks. * The rubber is separated from the metal plate of the transmission/transaxle mount. * The rubber is split through the center of the transmission/transaxle mount. 6. If there is movement between the metal plate of the transmission/transaxle mount and its attaching points, lower the transmission/transaxle on the transmission/transaxle mount. Tighten the bolts or nuts attaching the transmission/transaxle mount to the frame or transmission/transaxle mount bracket. 7. Remove the jackstand and block of wood from under the vehicle. 8. Lower the vehicle. Page 8297 Keyless Entry Transmitter: Tools and Equipment Special Tools Page 1468 Page 10066 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 9303 Sunroof / Moonroof Module: Locations Passenger Compartment/Roof Component Views Roof/Headliner Components (CF5) 1 - Sunroof Motor (part of the Sunroof Control Module) 2 - Sunroof Control Module Page 5999 A/T Controls - Downshift Hesitation/Delayed Shifting PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 8016 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Front Passenger Presence System (PPS) Module Inflatable Restraint Sensing and Diagnostic Module (SDM) Page 6013 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to auto range to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Heated Oxygen Sensor Replacement - Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 1 Heated Oxygen Sensor Replacement - Sensor 1 Page 6093 Accessory Power Outlet 1. Ignition OFF, remove the X80 accessory power receptacle - 110 V AC. 2. Test for greater than 1 M ohm between terminal 3 and terminal 6. ‹› If less than the specified range, replace the X80 accessory power receptacle - 110 V AC. 3. Test for less than 3 ohm between the following terminals: * The terminal 3 and the applicable receptacle terminal * The terminal 6 and the applicable receptacle terminal ‹› If greater than the specified range, replace the X80 accessory power receptacle - 110 V AC. 4. Test for infinite resistance between terminal 4 and terminal 1. ‹› If not the specified value, replace the X80 accessory power receptacle - 110 V AC. 5. Connect an AC powered device to the X80 accessory power receptacle - 110 V AC. 6. Test for less than 3 ohm between terminal 4 and terminal 1. ‹› If greater than the specified range, replace the X80 accessory power receptacle - 110 V AC. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * 120-Volt Accessory Power Receptacle Replacement (See: Service and Repair/120-Volt Accessory Power Receptacle Replacement) * Control Module References (See: Testing and Inspection/Programming and Relearning) for control module replacement, setup, and programming Page 2139 3. Install the heater outlet hose to the heater core. 4. Reposition the heater outlet hose clamp at the heater core using the J 38185. 5. Install the surge tank to the surge tank bracket. 6. Fill the coolant. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). Page 1993 Note: It may ease removal of the balance shaft drive chain to get all the slack in the chain between the crankshaft and water pump sprockets. 22. Remove the balance shaft drive chain (7). 23. Remove the balance shaft drive sprocket. Installation Procedure 1. If replacing the balance shaft timing chain, perform the following steps, if not proceed to step 10. 2. Install the balance shaft drive sprocket. Note: If the balance shafts are not properly timed to the engine, the engine may vibrate or make noise. 3. Install the balance shaft drive chain (7) with the colored link lined up with the marks on the balance shaft sprockets and the balance shaft drive sprocket. There are 3 colored links on the chain. Two are chrome and one is copper. Use the following steps in order to line up the links with the sprockets. 1. Place the copper link (5) so that it lines up with the timing mark (2) on the intake side balance shaft sprocket. Page 5558 Radio Antenna Module Page 6894 Power Steering Fluid Reservoir: Service and Repair Power Steering Fluid Reservoir Replacement Power Steering Fluid Reservoir Replacement Page 6204 For vehicles repaired under warranty, use the table. Disclaimer Page 7918 3. Disconnect the seat to body harness connector (1). Disconnect the seat airbag connector (2). Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing into the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Slide the conduit away on the seat airbag harness and remove just enough tape on the body harness to access the wires to install the terminals and seals. Note Use caution when stripping insulation. Take care not to cut through the wire strands. 5. Slide the wire seals onto all four leads back enough to enable removal of the insulation. Install the blue seals (1) on the body harness and the white seals (2) on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Page 5177 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Page 9033 Trim Panel: Service and Repair Body Lock Pillar Lower Trim Panel Replacement Body Lock Pillar Lower Trim Panel Replacement Page 4011 Page 9349 Note: Transfer the air deflector guides to the new air deflector. The air deflector guides can be replaced separately if damaged. 1. Install the guides to the air deflector. 2. Position the sunroof air deflector to the sunroof module. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the sunroof air deflector screws (1) to the sunroof module (2) and tighten to 3 Nm (26 lb in). Page 6351 Inflatable Restraint Front End Sensor - Left Inflatable Restraint Front End Sensor - Right Page 2421 Camshaft Position (CMP) Sensor - Intake (LAT or LE5 or LE9) Page 4308 Transmission Speed Sensor: Service and Repair 6T70/6T75 - Automatic Transmission Output Speed Sensor Replacement Output Speed Sensor Replacement Input Speed Sensor Replacement Input Speed Sensor Replacement Page 10009 Page 3049 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 5060 Battery Control Module: Diagrams Component Connector End Views Generator Battery Disconnect Control Module X1 (LAT) Generator Battery Disconnect Control Module X2 (LAT) Page 6225 Camshaft Position (CMP) Actuator Solenoid Valve - Intake (LE5 or LE9) Camshaft Position (CMP) Sensor (LZ4 or LZE) Locations Knock Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Lower Front and Rear of the Engine Components (LY7) Page 5913 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 3673 Control Module: Diagrams Component Connector End Views Automatic Transmission Auxiliary Fluid Pump Control Module (HP7 with ME7) Transmission Control Module (TCM) (ME7) Engine Controls - MIL ON/DTC P0172 Set Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P0172 Set TECHNICAL Bulletin No.: 10-06-04-004A Date: January 13, 2011 Subject: Intermittent Illumination of Malfunction Indicator Lamp (MIL)/Check Engine Light, DTC P0172 Set (Verify Alcohol Content Information in PCM) Models: 2010 Chevrolet Malibu Equipped with 2.4L 4 Cylinder Engine (VINs B, 0 - RPOs LE5, LE9) Please refer to GWM/IVH Supercede: This bulletin is being revised to update the engine type codes. Please discard Corporate Bulletin Number 10-06-04-004 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an intermittent illumination of the malfunction indicator lamp (MIL)/check engine light. Technicians may find a DTC P0172 set. Correction Use the procedure below to determine if the PCM has the incorrect alcohol content information. 1. Verify the actual measured percentage of alcohol content using the J-44175-A tester. Refer to Alcohol in Fuel Diagnosis in SI. If the actual alcohol is less than 15%, determine the "Fuel Alcohol Content" using the Tech 2(R). 2. Install the Tech 2(R) and build the vehicle as a 2010 and select Powertrain. 3. Build the vehicle with an LE9 engine (even if it has the LE5 engine). - Select Special Functions. - Select Fuel System (F2). Page 5552 Park/Neutral Position (PNP) Switch (ME7 or MN5) Page 7944 6. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals on to the bare wire using the J38125-7 crimp tool, jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 7. Position the wire seal to the terminal and crimp the seal and insulation using the J-38125-6 crimp tool, jaw 1 (1). The completed terminal and seal should appear as shown above (body harness connector shown). Note Avoid getting solder on the terminal end or overheating the terminal. Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. 8. Solder all four terminals at the wire crimp. 9. Slide the two body harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Page 5657 Blower Motor Control Module (C68) Interior - Gap At Rear Edge Of Shifter Trim Plate Console: Customer Interest Interior - Gap At Rear Edge Of Shifter Trim Plate TECHNICAL Bulletin No.: 08-08-49-012B Date: September 21, 2009 Subject: Gap at Rear Edge of Front Floor Console Shifter Trim Plate (Align Mounting Tab) Models: 2008-2010 Chevrolet Malibu Supercede: This bulletin is being revised to add the 2010 model year and to update the Correction information. Please discard Corporate Bulletin Number 08-08-49-012A (Section 08 - Body and Accessories). Condition Some customers may comment on a gap at the rear edge of the floor console shifter trim plate. Cause This condition may be caused by the front floor console accessory trim plate rear clips not fully engaging with the clip slots in the console base. Correction Use the following steps to remove the front floor console accessory trim plate and inspect the trim plate clip towers, clips and the console clip slots for damage. If no damage is found, reinstall the trim plate as described in the procedure. 1. Set the parking brake. 2. Turn the ignition key to the ON position with the engine off (the engine should not be running). 3. Depress the brake pedal and place the shifter into the neutral ("N") position. Note Release the shifter boot from the shifter knob by pulling the boot retainer down in order to gain access to the shift knob front retaining screw. 4. Remove the shift control knob. Refer to Floor Shift Control Knob Replacement in SI. 5. Remove the front floor console trim plate. Refer to Front Floor Console Accessory Trim Plate Replacement in SI. 6. Inspect the underside of the shifter console trim plate for the four white attaching clips and their rib structures. - Inspect all of the shifter plate attachments, including the two small forward tabs. If none of the attachments are damaged and the shifter plate forward tip up bin lid functions properly, DO NOT REPLACE the shifter trim plate. - If any of the four attaching clips are damaged or bent, the console shifter trim plate may need to be replaced. 7. Remove the left and right console side extension panels to provide access to the clip slots in the console base from below. Refer to Front Floor Console Extension Panel Replacement in SI. 8. Position the front floor console accessory trim plate for installation. Refer to Front Floor Console Accessory Trim Plate Replacement in SI. Page 3490 3. Connect the engine wiring harness electrical connector (2) to the ETC (1). 4. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 5. Perform the Throttle Learn procedure. Refer to Throttle/Idle Learn (See: Testing and Inspection/Programming and Relearning/Throttle Learn). Page 773 2. Measure from the same end as earlier, and slide the current sensor to that measurement on the negative battery cable. 3. Install the battery negative cable. Refer to Battery Negative Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). Diagrams Keyless Entry Receiver: Diagrams Component Connector End Views Remote Control Door Lock Receiver (RCDLR) Page 5201 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 5111 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Page 8620 Pedal Positioning Sensor: Diagrams Component Connector End Views Brake Pedal Position (BPP) Sensor Page 10064 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Page 8976 8. Install the three pieces of foam to the attaching bracket starting at the top center inside the bracket and proceed down across the fuel lines, then at the inside of the bracket at the left and right positions of the center piece of foam. Finally, install the last two pieces of foam to the inside bracket at the left and right extended sides behind the retaining holes as shown above. 9. Reposition the radiator surge tank back onto the bracket and seat the two retaining tabs on the tank. 10. Drive the vehicle to verify that the noise is no longer present. Parts Information Order Adhesive Back Shim Stock from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 7001 2. Apply grease from the service kit to the indicated locations. Important: The steering gear boot must seat in the appropriate groove on the steering gear. 3. Install the steering gear boot over the steering gear inner tie rod and onto the steering gear. 4. Using pliers J 22610, crimp the inner steering gear boot clamp. 5. Install the outer steering gear boot clamp. 6. Install a new steering gear inner tie rod nut in the same position the prior one was removed from. 7. Install the rack and pinion outer tie rod end. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 8. Adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Page 6159 Fuse Block - Underhood Top View (LE5 or LE9) Page 1789 2. Install the piston into its original bore using the EN-43966-1 - guides. 3. Lightly tap the top of the piston with a wooden hammer handle. 4. When installing the piston and the connecting rod, the stamped mark on the piston must point to the front of the engine. 5. Hold the EN-8037 - compressor firmly against the engine block until all the piston rings have entered the cylinder bore. 6. Install the connecting rod caps onto their original connecting rods. 7. Align the numbers placed on the connecting rod and the connecting rod cap during removal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the new connecting rod bolts and nuts. * On the first pass, tighten the nuts evenly to 25 Nm (18 lb ft). * On the final pass, use the EN-45059 - meter in order to tighten the nuts an additional 100 degrees. 9. Measure the connecting rod side clearance with a feeler gauge. The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in). 10. Install the cylinder head. Refer to Cylinder Head Replacement (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement). 11. Install the oil pan. Refer to Oil Pan Replacement (See: Engine Lubrication/Oil Pan/Service and Repair). Locations Throttle Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left Side of the Instrument Panel Components (1 of 2) 1 - Brake Pedal Position (BPP) Sensor 2 - Accelerator Pedal Position (APP) Sensor 3 - Accelerator Pedal 4 - Brake Pedal Page 2232 7. Remove the upper exhaust manifold bolts. 8. Remove the right catalytic converter. Refer to Catalytic Converter Replacement - Right Side (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Right Side). 9. Remove the lower exhaust manifold bolts. 10. Remove the exhaust manifold. 11. Remove and discard the exhaust manifold gasket. Installation Procedure 1. Install a NEW exhaust manifold gasket onto the cylinder head studs. 2. Install the exhaust manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the exhaust manifold bolts and tighten to 20 Nm (15 lb ft). 4. Install the right catalytic converter. Refer to Catalytic Converter Replacement - Right Side (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Right Side). Page 3724 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Component Location Component Location Component Locations 1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear Support Assembly Page 401 Page 809 1. Install the fuel level sensor (1) to the alignment feature (2). 2. Allow the locking tab (2) to lock into place. 3. Connect the fuel level sensor electrical connector (1). 4. Install the fuel pump module assembly. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Page 1756 Camshaft: Service and Repair Exhaust Camshaft and Valve Lifter Replacement Exhaust Camshaft and Valve Lifter Replacement Removal Procedure 1. Remove the exhaust camshaft position actuator. Refer to Camshaft Position Exhaust Actuator Replacement (See: Camshaft Position Exhaust Actuator Replacement). Note: Remove each bolt on each cap one turn at a time until there is no spring tension pushing on the camshaft. 2. Mark the bearing caps to ensure they are installed in the original position. 3. Remove the bearing cap bolts. 4. Remove the bearing caps. Page 3784 Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (MN5) Page 5231 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Page 10507 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 5685 X208 Inline Harness Connector End Views X208 I/P Harness to Body Harness Page 1314 13. If the fluid was changed, reset the transmission oil life monitor if applicable. Fluid Condition Inspection * Inspect the fluid color. The fluid should be red in color. The fluid may also turn brown form normal use, and does not always indicate contamination. Note: Fluid that is very dark or black and has a burnt odor usually indicates contamination or overheating. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal particles or other debris which may indicate transmission damage. Refer to Road Test (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview/6T30/6T40/6T45 - Automatic Transmission) to verify transmission operation. Change the transmission fluid if no other conditions are found. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic Procedures/6T30/6T40/6T45 - Automatic Transmission/Engine Coolant/Water in Transmission). Locations Trunk / Liftgate Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 1446 Fuse Block - Underhood Top View (LZ4 or LZE) Page 1093 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Page 6819 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the strut to knuckle nuts. Tighten the nuts to 120 Nm (89 lb ft). Page 3059 Engine Control Module (ECM) X1 (LZ4 or LZE) Page 9518 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Engine Coolant Crossover Pipe Replacement Coolant Line/Hose: Service and Repair Engine Coolant Crossover Pipe Replacement Engine Coolant Crossover Pipe Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Fuel Injector Sight Shield Replacement (). 2. Remove the generator. Refer to Generator Replacement (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). 3. Remove the drive belt idler pulleys. Refer to Drive Belt Idler Pulley Replacement (). 4. Remove the power steering pump. Refer to Power Steering Pump Replacement (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering Pump Replacement). 5. Reposition the radiator surge tank inlet hose clamp (1) at the surge tank inlet pipe. 6. Remove the radiator surge tank inlet hose from the inlet pipe. Position the hose out of the way. Page 6822 Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections in order to ensure correct alignment readings: * Inspect for visible damage to the suspension components and replace as necessary. * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label) and Tire Diagnosis - Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear). * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Specifications). * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis). * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Steering/Specifications). * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle). * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Note: * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear toe adjustment first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Front Camber Adjustment Front Camber Adjustment Page 1880 1. Place the engine mount onto the side rail studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the engine mount to side rail bolts (2) and tighten to 50 Nm (37 lb ft). Note: The engine mount to bracket bolts must be hand started. Do not pry the engine mount to align the holes. 3. Install the engine mount to bracket bolts (1) and tighten to 90 Nm (66 lb ft). 4. Remove the hydraulic floor jack from under the oil pan. 5. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). Locations Variable Valve Timing Solenoid: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) Page 10383 Page 6463 Accessory AC/DC Power Control Module X2 (KV1) 6T30/6T40/6T45 - Automatic Transmission Shift Cable: Adjustments 6T30/6T40/6T45 - Automatic Transmission Range Selector Lever Cable Adjustment Warning The automatic transaxle range selector cable is made out of two cable sections. After initial connection never separate the two metal couplings from one another. Integrity of the connection of the two metal couplings will be lost if separation of the two metal couplings occurs. When servicing the transaxle remove the cable at the automatic transaxle range selector lever and at the automatic transaxle range selector cable bracket. If either section of the cable needs to be replaced, replace both of the cable sections. Loss of connection integrity of the two metal couplings can cause loss of transaxle shift control which could result in personal injury. Note: Adjust the automatic transmission range selector cable while the transmission and the gear selector are in the Park position only. Failure to do so may cause mis-adjustment. 1. Set the park brake and chock the wheels. 2. Verify the transmission range select lever is in the park position. 3. Verify the transmission manual shift lever is in the park position. 4. Release the range select cable adjuster clip (1). Page 2217 Catalytic Converter: Service and Repair Catalytic Converter Replacement - Right Side Catalytic Converter Replacement - Right Side Special Tools J 39194-B Heated Oxygen Sensor Wrench Removal Procedure Caution: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. Caution: The use of excessive force may damage the threads in the exhaust manifold/pipe. Note: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S. Note: The HO2S may be difficult to remove when the engine temperature is less than 48°C (120°F). 1. Remove the muffler assembly. Refer to Exhaust Muffler Replacement (See: Muffler/Service and Repair). 2. Remove the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement (See: Steering and Suspension/Suspension/Stabilizer Bar/Service and Repair/Rear Suspension). 3. Remove the connector position assurance (CPA) retainer (3). 4. Disconnect the lower right heated oxygen sensor (HO2S) electrical connector from the engine wiring harness electrical connector (2). Page 7340 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 3198 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement Special Tools J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. Warning Page 5406 Courtesy Lamp Procedures Wiper Blade: Procedures Wiper Blade Element Cleaning Wiper Blade Element Cleaning Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full strength washer solvent. Then rinse the blade assemblies with clear water. Wiper Chatter Repair Wiper Chatter Repair Some vehicles may exhibit a condition where the windshield wipers chatter and/or wipe unevenly. Several items may contribute to this condition. To completely repair this condition, the following two items listed should be tested and repaired as necessary. * Clean the windshield glass. Refer to Windshield Glass Cleaning (See: Windows and Glass/Windshield/Service and Repair/Procedures). * Clean the wiper blade elements. Refer to Wiper Blade Element Cleaning (See: Wiper Blade Element Cleaning). Page 8361 Digital Video Disc (DVD) Control Module X6 (SPO Accessory) (UJ5) Page 5462 Engine Cooling Fan - Right Engine Oil Pressure (EOP) Sensor (LZ4 or LZE) Engine Oil Pressure (EOP) Switch (LAT or LE5 or LE9) Page 462 Transmission Control Module (TCM) (MN5 with LZ4 or LZE) Page 5972 Page 10074 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 4419 Flex Plate: Service and Repair Engine Flywheel Replacement Special Tools * J 38122-A Crankshaft Balancer Holder * J 45059 Angle Meter Removal Procedure 1. Remove the transaxle. Refer to Transmission Replacement (See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement). 2. Have an assistant install the J 38122-A, and a breaker bar to the crankshaft balancer in order to prevent the flywheel from rotating when loosening the flywheel bolts. Note: It may be necessary to remove the chamfer (bevel) from the edge of an 18 mm socket in order to get full engagement on the thin-headed flywheel bolts. 3. Loosen, remove and discard the flywheel bolts. Note: Do not orientate the flywheel to the crankshaft. It is balanced separately from the engine. 4. Remove the flywheel. 5. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft. Installation Procedure Page 2925 2. Ignition ON, verify a test lamp illuminates between the B+ circuit terminal 16 at the DLC and ground. ‹› If the test lamp does not illuminate, test the voltage supply circuit for a short to ground or an open/high resistance. 3. If all circuits test normal, refer to the scan tool/CANdi module user guide. Repair Instructions Perform the Diagnostic Repair Verification (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the repair. Page 6509 X180 Inline Harness Connector End Views X180 Left Repeater Lamp Harness to Forward Lamp Harness Page 1078 1. Position the level indicator seal (3) to the washer solvent container (1), pressing in until fully seated. 2. Using full strength windshield washer solvent on the seal, position the washer solvent level indicator (4) to the washer solvent container (1), pressing in until fully seated. 3. Connect the washer solvent level indicator electrical connector. 4. Install the front wheelhouse panel splash shield. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 5. Fill the washer solvent container with windshield washer solvent. Page 396 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9990 Cruise Control: Testing and Inspection Cruise Control Malfunction Cruise Control Malfunction Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The cruise control switch is an input to the body control module (BCM). The BCM monitors the cruise control set/coast and resume/accelerate switch signal circuit in order to detect when the driver has requested to perform a cruise control function. The BCM detects a specific voltage signal on the cruise control switch signal circuit when a switch is applied. The BCM sends a serial data message to the engine control module (ECM), indicating the status of the cruise control switches. Reference Information Schematic Reference Cruise Control Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Cruise Control Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Engine ON, while rotating the steering wheel to both steering stops, observe the scan tool Cruise Control Switch parameter while pressing each of the cruise control switches. The parameter should toggle between On, Off, Resume and Set as the applicable switch is pressed. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the steering wheel controls switch - left. 2. Ignition OFF, test for less than 10 ohms between the ground circuit terminal 7 and ground. Page 9036 Trim Panel: Service and Repair Body Rear Corner Upper Garnish Molding Replacement Body Rear Corner Upper Garnish Molding Replacement Body Lock Pillar Lower Trim Panel Replacement Body Lock Pillar Lower Trim Panel Replacement Page 4138 1 - Control Valve Body Cover Assembly 2 - Transmission Fluid Level Indicator Assembly 3 - Fluid Level Indicator Tube - Model Dependent 4 - Fluid Level Indicator Tube Seal - Model Dependent 5 Control Valve Body Cover Assembly Gasket 6 - Control Valve Body Cover Stud 7 - Control Valve Body Cover Bolt 8 - Control Valve Body Bolt 9 - Control Valve Body Bolt 10 - Control Valve Body Cover Wiring Connector Hole Seal 11 - Control Solenoid Valve Spring 12 - Control Valve Body Bolt 13 - Control Valve Body Bolt 14 - Control Valve Body Bolt 15 - Control Solenoid (w/Body and TCM) Valve Assembly 16 - Control Solenoid (w/Body and TCM) Filter Plate Assembly 17 - Manual Shaft Detent Assembly 18 - Control Valve Body Assembly 19 - A/Trans Output Speed Sensor Assembly 20 - A/Trans Output Speed Sensor Bolt 21 - A/Trans Case Assembly 22 - Torque Converter Housing Outer Seal 23 - Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly 24 Front Differential Drive Pinion Gear Lube Tube Page 5466 Fog Lamp - Right Front (T96) Page 5263 To help avoid personal injury, always treat the accessory power receptacle, accessory DC/AC power inverter module, AC circuit wires, and connectors as if AC high-voltage is present. 1. Ignition OFF, test for 12.0-15.0 V across the battery terminals. ‹› If no within the specified range, refer to Battery Inspection/Test (See: Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). 2. Ignition ON, connect an AC power extension cord to the X81 accessory power receptacle - 110 V AC. Inserting the extension cord plug into the X81 accessory power receptacle - 110 V AC turns the T1 accessory DC/AC power inverter module ON. 3. Verify the receptacle indicator light comes on. 4. Test for 110-120 V between the terminals at the extension cord. 5. Test for 59-61 Hz AC across the line A and line B terminals of the extension cord. Circuit/System Testing 1. Ignition OFF, disconnect the harness connectors at the T1 Accessory DC/AC power inverter module. 2. Test for less than 10 ohm between the ground circuit terminal 1 X2 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Verify that a test lamp illuminates between the B+ circuit terminal 2 X2 and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 4. Ignition ON, test for less than 1.0 V between the AC circuit terminals listed below and ground: * Terminal 4 X1 * Terminal 6 X1 ‹› If greater than the specified range, test the AC circuit for a short to voltage. 5. Ignition OFF, test for infinite resistance between the AC circuit terminals listed below and ground: * Terminal 4 X1 * Terminal 6 X1 ‹› If less than the specified value, test the AC circuit for a short to ground. 6. Disconnect the harness connector at the X81 accessory power receptacle - 110 V AC. 7. Ignition ON, verify a test lamp illuminates between the control circuit terminal 4 and ground. ‹› If the test lamp does not illuminate, test the control circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the K9 BCM. 8. Verify a test lamp does not illuminate between the signal terminal 1 and ground. ‹› If the test lamp illuminates, test the signal circuit for a short to voltage. If the circuit tests normal, replace the T1 Accessory DC/AC power inverter module. 9. Connect a 3 A fused jumper between the control terminal 4 and the signal terminal 1. 10. Ignition ON, verify that a test lamp illuminates between the T1 Accessory DC/AC power inverter module signal circuit terminal 2 X1 and ground. ‹› If the test lamp does not illuminate, test the signal circuit for a short to ground or an open/high resistance. 11. Ignition OFF, connect the harness connectors at the T1 Accessory DC/AC power inverter module. Ignition ON, test for 110-120 V AC between the X81 accessory power receptacle - 110 V AC terminal 3 and 6. ‹› If not within the specified range, check both AC circuits for an open/high resistance. If all circuits test normal, replace the T1 Accessory DC/AC power inverter module. 12. If all circuits test normal, replace the X81 accessory power receptacle - 110 V AC. Component Testing Page 2418 Camshaft Position (CMP) Sensor - Bank 2 Exhaust (LY7) Page 10003 Page 2393 Page 9419 Power Seat Switch: Service and Repair Lumbar Switch Replacement Lumbar Switch Replacement Page 4490 Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 8. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. System Diagnosis Idle Speed: Testing and Inspection Throttle/Idle Learn Description The engine control module (ECM) learns the idle position of the throttle plate to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned. A vehicle that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero. The idle may be unstable or a DTC may set if the learned values do not match the actual airflow. Conditions for Running the Throttle Learn Procedure * DTCs P0101, P0102, P0103, P0107, P0108, P0111, P0112, P0113, P0506, and P0507 are not set. * The engine speed is between 450-4,000 RPM. * The manifold absolute pressure (MAP) is greater than 5 kPa. * The mass air flow (MAF) is greater than 2 g/s. * The ignition 1 voltage is greater than 10 volts. Throttle Learn With Scan Tool-Reset 1. Ignition ON, engine OFF. With a scan tool, perform the Idle Learn Reset in Module Setup. 2. Start the engine, monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation parameter value should equal 0 percent and the engine should be idling at a normal idle speed. ‹› If the engine is not idling normally, proceed with the Learn portion of the diagnostic. 3. Clear the DTCs and return to the diagnostic that referred you here. Without Scan Tool-Learn Important: Do NOT perform the Without Scan Tool-Learn procedure if DTCs are set. Refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle). 1. The engine speed is between 450-4,000 RPM. 2. The manifold absolute pressure (MAP) is greater than 5 kPa. 3. The mass air flow (MAF) is greater than 2 g/s. 4. The ignition 1 voltage is greater than 10 volts. 5. Start and idle the engine in Park for 3 minutes. 6. With a scan tool, monitor desired and actual RPM. 7. The ECM will start to learn the new idle cells and Desired RPM should start to decrease. 8. Ignition OFF for 60 seconds. 9. Start and idle the engine in Park for 3 minutes. Important: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. 10. After the 3 minute run time the engine should be idling normal. ‹› If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles. 11. After the drive cycle, the engine should be idling normally. ‹› If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6. 12. Once the engine speed has returned to normal, clear DTCs. Page 2195 20. Install the exhaust heat shield. 21. Install the exhaust heat shield bolts. Tighten the studs to 22 Nm (16 lb ft). 22. Install the radiator outlet hose to the thermostat cover. 23. Position the radiator outlet hose clamp at the thermostat cover. Page 6443 Vehicle Communication Interface Module (VCIM) X2 (UE1) Page 6737 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Service and Repair Windshield Washer Hose: Service and Repair Windshield Washer Hose Replacement Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. For example, a failure condition exists if the ECM detects low voltage when the MIL is commanded OFF, or high voltage when the MIL is commanded ON. Reference Information Schematic Reference * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) * Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification 1. Ignition ON, command the MIL ON and OFF with a scan tool. The MIL should turn ON and OFF as commanded. 2. Command the MIL ON and OFF with a scan tool while observing the following control circuit status parameters: * MIL Ckt. Short Gnd Test Status * MIL Ckt. Open Test Status * MIL Ckt. Short Volts Test Status Each parameter should change from OK and Not Run or from Not Run and OK. 3. Operate the vehicle within the Conditions for Running the DTC to verify that the DTC does not reset. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing 1. Ignition ON, verify that the instrument panel cluster (IPC) warning indicators are illuminated. ‹› If the IPC warning indicators are not illuminated, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 2. Ignition OFF, disconnect ECM X1 harness connector. Ignition ON, the MIL should not illuminate. Page 9146 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2818 Page 6024 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2185 Thermostat: Service and Repair Engine Coolant Thermostat Replacement Removal Procedure 1. Partially drain the cooling system. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). 2. Remove the radiator outlet hose from the thermostat housing. 3. Remove the heater inlet and outlet hoses. 4. Remove the surge tank outlet hose. 5. Remove the thermostat housing bolts (1). 6. Remove the housing. 7. Remove the thermostat (2) and discard the thermostat gasket. Installation Procedure Page 9897 Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 5331 Fuse Block - Underhood Top View (LY7) Page 67 Pedal Positioning Module: Diagrams Component Connector End Views Accessory Power Outlet - I/P Accessory Power Outlet - 110V AC (KV1) Page 4683 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Bracket Replacement Brake Pressure Modulator Valve Bracket Replacement Removal Procedure 1. Remove the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement (See: Brake Pressure Modulator Valve Replacement). 2. Remove the BPMV bolt (1). 3. Remove the bracket (1) from the BPMV. Installation Procedure Page 4679 4. Install the BPMV and bracket assembly. 5. Install the 3 BPMV bracket nuts (1) and tighten to 10 Nm (89 lb in). 6. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. Connect the master cylinder secondary brake pipe fitting (1) and tighten the fitting to 32 Nm (24 lb ft). Page 1096 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Page 3309 1. Install and close the underbody retainers (5). 2. Install and close the front of dash fuel feed/EVAP pipe retainers (4). 3. Install and close the upper fuel feed/EVAP pipe retainer (3). 4. Position the fuel feed/EVAP pipe assembly to the vehicle. 5. Install the brake pipes to the retainers. 6. Install the brake, fuel and EVAP pipe retainers (5) to the underbody studs. 7. Remove the caps from the chassis fuel and EVAP pipes. 8. Connect the fuel tank EVAP pipe quick connect fitting (2) to the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 9. Connect the fuel tank fuel feed pipe quick connect fitting (1) to the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Symptoms - Seat Heating and Cooling Seat Heater: Testing and Inspection Symptoms - Seat Heating and Cooling Symptoms - Seat Heating and Cooling Important: Review the system description in order to familiarize yourself with the system functions. Refer to Heated Seats Description and Operation (See: Description and Operation). Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the heated seat system. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Symptom List Refer to Heated Seat Inoperative (See: Heated Seat Inoperative) in order to diagnose the symptom. Page 8864 Trunk / Liftgate Latch: Service and Repair Rear Compartment Lid Latch Replacement Page 6878 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Page 4806 Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. Note: Do NOT disconnect the hydraulic brake flexible hose from the caliper. 6. Remove the brake caliper and the caliper mounting bracket (1) as an assembly from the steering knuckle and support the assembly with heavy mechanic's wire (2), or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose. Refer to Front Brake Caliper Bracket Replacement (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Bracket Replacement). 7. Matchmarks the position of the brake rotor to the wheel studs. 8. Remove the brake rotor. Installation Procedure Note: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 1. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J 41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Install the brake rotor (1) to the hub/axle flange (2). Use the matchmarks made prior to removal for proper orientation to the flange. 5. Remove the support, and install the brake caliper and the brake caliper bracket as an assembly to the steering knuckle. Refer to Front Brake Caliper Bracket Replacement (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Bracket Replacement). 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing (See: Brake Pad/Service and Repair/Procedures). Rear Brake Rotor Replacement Rear Brake Rotor Replacement Page 4906 4. Disconnect the brake pipes from the master cylinder. Note: Cap the exposed brake pipe fitting to prevent brake fluid loss and contamination. 5. Plug the master cylinder outlet ports. 6. Remove the 2 master cylinder mounting nuts. 7. Remove the master cylinder. 8. Inspect the master cylinder-to-vacuum brake booster seal. Replace the seal if it is damaged. 9. If replacing the master cylinder, remove the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement (See: Brake Fluid Reservoir/Service and Repair). Installation Procedure 1. If removed, install the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement (See: Brake Fluid Reservoir/Service and Repair). 2. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding (See: Procedures/Master Cylinder Bench Bleeding). 3. Check to ensure that the master cylinder-to-vacuum brake booster seal is properly seated on the master cylinder barrel. Page 10234 Frequently Asked Questions Disclaimer Page 1835 3. Install the ignition coils. Refer to Ignition Coil Replacement (See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair). 4. Position the engine wiring harness and install the clips (4) to the cover. 5. Connect the engine wiring harness electrical connectors (2, 3) to the intake and exhaust camshaft position actuator solenoid valves. 6. Install the battery box cover, LAT only. 7. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 2392 Page 278 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 6317 Headlamp - Left Low Beam Headlamp - Right High Beam Page 8678 Note: Note the number and location of the factory welds for installation of the impact bar bracket front bumper 6. Locate and drill out all the factory welds from the outside surface of the rail. 7. Remove the front bumper impact bar bracket. Installation Procedure Description and Operation Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Camshaft Position (CMP) Actuator System The camshaft position (CMP) actuator system is an electro-hydraulic operated device used for a variety of engine performance and operational enhancements. These enhancements include lower emission output through exhaust gas dilution of the intake charge in the combustion chamber, a broader engine torque range, and improved fuel economy. The CMP actuator system accomplishes this by changing the angle or timing of the camshaft relative to the crankshaft position. The CMP actuator simply allows earlier or later intake and exhaust valve opening during the four stroke engine cycle. The CMP actuator cannot vary the duration of valve opening, or the valve lift. During engine OFF, engine idling conditions, and engine shutdown, the camshaft actuator is held in the Park position. Internal to the CMP actuator assembly is a return spring and a locking pin. During non-phasing modes of the camshaft, the return spring rotates the camshaft back to the Park position, and the locking pin retains the CMP actuator sprocket to the camshaft. CMP Actuator System Operation The camshaft position (CMP) actuator system is controlled by the engine control module (ECM). The ECM sends a signal to a CMP actuator solenoid in order to control the amount of engine oil flow to a Cam Actuator passage. The pressurized engine oil is sent to unseat the locking pin, and to the vane and rotor assembly of the CMP actuator. There are 2 different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The Cam Actuator is attached to a camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position (CKP). Engine oil pressure (EOP), viscosity, temperature and engine oil level can have an adverse affect on Cam Actuator performance. Page 7653 Heater Hose: Service and Repair Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement Page 6139 Fuse: Locations Rear Compartment Fuse Block - Owners Manual REAR COMPARTMENT FUSE BLOCK The rear compartment fuse block is located in the trunk of the vehicle. Access the fuse block through the trunk panel on the driver side of the rear cargo area. Page 3574 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. (Intake CMP shown, exhaust CMP similar). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect engine wiring harness electrical connector (5) to the exhaust CMP sensor (4). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). A/C - Poor Cooling Performance/Condenser Fan Fuse Blown Fuse: All Technical Service Bulletins A/C - Poor Cooling Performance/Condenser Fan Fuse Blown TECHNICAL Bulletin No.: 09-01-38-005 Date: October 09, 2009 Subject: Poor A/C Performance, Cooling Fan Fuse Blown (Install Revised Fuse And Wiring) Models: 2008-2010 Chevrolet Malibu 2006-2010 Pontiac G6 2007-2010 Saturn AURA All with RPO LY7, LZ4, LZ9 or LZE V6 Engine Condition Some customers may comment on poor A/C cooling performance. Technicians may find that the cooling fan fuse is blown. Cause High cooling fan start up loads may cause the 30-amp cooling fan fuse, located in the underhood fuse block, to blow. The lack of air flow through the A/C condenser, caused by the inoperative high-speed cooling fan, may affect the condenser's ability to dissipate heat. Correction Use the following procedure to install a heavier gauge power feed wire from the underhood fuse block to the cooling fan. After the wiring update is completed, replace the 30-amp cooling fan fuse in the underhood fuse block with a 40-amp fuse. 1. Disconnect and remove the battery. Refer to Battery Replacement in SI. 2. Remove the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 3. Disconnect the underhood fuse block from it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. It is only necessary to raise the fuse block enough to access the harness connectors. Do not remove the complete assembly from the vehicle. 4. Locate the engine wiring harness junction block assembly (X1) on the back (underside) of the underhood fuse block and disconnect it from the underhood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 5. Find pin A2, Circuit 532, cooling fan motor supply voltage. Refer to Electrical Center Identification Views, Fuse Block-Underhood X1 in SI. 6. Remove the harness back cover. Remove the TPA (terminal position assurance) clip and remove connector A2 from the junction block. Cut the terminal off and tape the wire end with electrical tape. 7. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 8. Locate the electrical connector to the right cooling fan and disconnect the wiring connector from the fan. 9. Disengage pin B, wire 3 GY, circuit 532, cooling fan motor supply voltage, from the connector housing (pull to seat terminal). Cut the terminal off of the wire and remove the wire from the connector housing. 10. Tape the end of the wire with electrical tape. 11. Prepare a 1.82 m (6 ft) section of automotive grade 5.0 mm (10 GA) wire and an equal length of 6 mm (1/4 in) flexible plastic conduit, GM P/N 12051375. 12. Run the new wire through the fan wire connector housing as shown. 13. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 14. Strip the wire insulation as required and install the terminal, GM P/N 12033997, on the wire. Secure the wire and terminal into the fan wire Page 10338 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 1315 Fluid - A/T: Testing and Inspection 6T70/6T75 - Automatic Transmission Transmission Fluid Level and Condition Check This procedure checks both the transmission fluid level, as well as the condition of the fluid itself. Caution: Use Dexron VI transmission fluid only. Failure to use the proper fluid may result in transmission internal damage. Note: Ensure the transmission has enough fluid in it to safely start the vehicle without damaging the transmission. With the vehicle off there must be at least enough fluid to wet the end of the dipstick bullet. This will ensure that there is enough fluid in the sump to fill the components once the vehicle is started. Level Checking Procedure 1. Park the vehicle on a level surface, apply the parking brake and place the shift lever in PARK (P). 2. Start the engine. 3. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in each range. Then move the shift lever back to PARK (P). 4. Allow the engine to idle 500-800 rpm for at least 1 minute. Release the brake pedal. 5. Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver Information Center or a scan tool. Note: If the fluid temperature is below the specified range, perform the following procedure to raise the fluid temperature to the specified range. 6. If the TFT reading is not within the required temperature ranges, allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached. Drive the vehicle in second gear until the fluid temperature is within the specified range. Note: Check the transmission fluid level when the TFT is between 180°F and 200°F (82°C and 93°C). The fluid level rises as fluid temperature increases, so it is important to ensure the transmission fluid temperature is within range. 7. Remove the dipstick and wipe it with a clean rag or paper towel. 8. Inspect the fluid color. The fluid should be red or dark brown. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal particles or other debris. A small amount of "friction" material is a "normal" condition. If large pieces and/or metal particles are noted in the fluid, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs of transmission internal damage noted, replace the fluid, repair the oil cooler, and flush the cooler lines. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic Procedures/6T70/6T75 - Automatic Transmission/Engine Coolant/Water in Transmission). 9. Install the dipstick and tighten. Wait three seconds and then remove it again. Note: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent assembly to ensure it is clean and unclogged. 10. Check both sides of the dipstick and read the lower level. Note: It is not necessary to get the fluid level all the way up to the MAX mark. Anywhere within the crosshatch band is acceptable. 11. Install and remove the dipstick again to verify the reading. 12. If the fluid level is not within the crosshatch band, and the transmission temperature is between 180°F and 200°F (82°C and 93°C), add or drain fluid as necessary to bring the level into the crosshatch band. If the fluid level is low, add only enough fluid to bring the level into the crosshatch band. Note: Do not add more than one pint (0.5L) at a time without rechecking the level. Once the oil is on the dipstick bullet, it will not take much more fluid to raise the fluid level into the crosshatch band. Do not overfill. Also, if the fluid level is low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/6T70/6T75 - Automatic Transmission/Fluid Leak Diagnosis). 13. If the fluid level is in the acceptable range, install the dipstick. 14. If the fluid was changed, reset the transmission oil life monitor if applicable. Fluid Condition Inspection * Inspect the fluid color. The fluid should be red in color. The fluid may also turn brown form normal use, and does not always indicate contamination. Page 6309 Generator X2 (LE5 or LE9) Generator X2 (LY7) Generator X2 (LZ4 or LZE) Page 3898 8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95. 10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body and transmission control module (TCM) assembly (5). Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 12. Remove the control solenoid valve assembly filter plate (6). * Discard the filler plate. It is not reusable. * Inspect the pressure switch manifold seals for damage or contamination. Replace the control solenoid valve assembly as necessary. * Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage around the PCS seals. Replace the upper channel plate as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (1). Page 9610 Page 8985 Front Floor Console Armrest Replacement Front Floor Console Armrest Replacement Page 849 1 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 2 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 3 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 Front and Right Side of the Engine Components (LY7) Page 7598 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Page 7444 2. Install the I/P pad. Refer to Instrument Panel Upper Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Upper Trim Panel Replacement). Page 1452 Fuse Block - Underhood X3 Page 5495 Heated Seat Control Module - Driver X2 (KA1) Page 7708 6. Remove the refrigerant filter from the line. Note: Cap all A/C components immediately to prevent system contamination. 7. Remove and discard the sealing washers. Installation Procedure 1. Uncap A/C components. 2. Install new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 3. Install the refrigerant filter into the line. 4. Install the line clip to the dash. Page 6354 Inflatable Restraint Roof Rail Module - Left Inflatable Restraint Roof Rail Module - Right Page 10056 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 6229 Camshaft Position (CMP) Sensor - Bank 2 Intake (LY7) Page 3511 Camshaft Position (CMP) Sensor - Bank 2 Intake (LY7) Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor Replacement - Intake Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (7) from the intake camshaft position (CMP) sensor (6). 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. Installation Procedure Page 10060 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2346 Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 1557 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Page 488 Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3 or HP7) Page 9598 Page 2708 * Throttle default mode-The ECM will turn OFF the throttle actuator motor, and the throttle will return to the spring loaded default position. * Forced idle mode-The ECM will perform the following actions: - Limit engine speed to idle positioning the throttle position, or by controlling the fuel and spark if the throttle is turned OFF. - Ignore the accelerator pedal input. * Engine shutdown mode-The ECM will disable fuel and de-energize the throttle actuator. Page 10421 Page 5546 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 2951 Manifold Pressure/Vacuum Sensor: Service and Repair Manifold Absolute Pressure Sensor Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 3. Reposition the EVAP canister purge tube (1) out of the way. 4. Disconnect the fuel injector wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor. Page 1988 Note: The timing chain tensioner must be removed to unload chain tension before the timing chain is removed. If it is not, the timing chain will become cocked and it will be difficult to remove. 6. Remove the timing chain tensioner. 7. Install a 24 mm wrench on the hex on the exhaust camshaft in order to hold the camshaft. 8. Remove and discard the exhaust camshaft actuator bolt (2). 9. Remove the exhaust camshaft actuator (1, 3) from the camshaft and timing chain. Page 2178 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LAT or LE5 or LE9) Engine Coolant Temperature (ECT) Sensor (LY7) Page 4663 Electronic Brake Control Module (EBCM) (LY7 or LZ4 or LZE) Page 9313 Page 6679 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. Page 2735 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 1412 Fuse Block - Underhood X5 (Battery Positive Cable) (without NVH) Fuse Block - Underhood X6 (Battery Positive Cable) Page 4060 Important: J 41102-1A must be used in order to install the axle seal to the correct depth. 1. Install a new output axle seal (3). Use J 41102-1A (2) with J 8092 (1). Lubricate the seal lip with transmission fluid. 2. Apply grease to the output shaft splines. Important: J 41228 must be used in order to install the sleeve to the correct depth. 3. Use J 41228 to install a NEW sleeve on the output axle shaft. 4. Install the collet into the output shaft snap ring groove with the collet attached to the threaded collet shaft. 5. Place the NEW sleeve over the collet. 6. Install the bearing and nut onto the threaded collet shaft. 7. Hold the collet shaft while tightening the nut in order to press the sleeve onto the output shaft. 8. Remove the J 41228. Page 8511 Speaker - Left Rear (UQ3) Speaker - Left Rear (UW5) Page 5390 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6058 Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Page 2919 Data Link Communications Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Testing Note: Each control module may need to be disconnected to isolate a circuit fault. Use the schematic to identify the following: * Control modules the vehicle is equipped with * High speed GMLAN serial data circuit terminating resistors * Control module locations on the high speed GMLAN serial data circuits * Each control module's high speed GMLAN serial data circuit terminals 1. Attempt to communicate with all control modules on the high speed GMLAN serial data circuit, refer to Data Link References (See: Initial Inspection and Diagnostic Overview). Communications should not be available with two or more control modules on the high speed GMLAN serial data circuit. ‹› If only one control module is not communicating, diagnose that control module only; refer to DTC U0100-U02FF (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U0100). 2. Disconnect the scan tool from the DLC. The following tests will be done at the DLC connector. 3. All access doors closed, ignition OFF for 60 seconds, test for less than 10 ohm between the ground circuit terminal 5 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 4. Ignition ON, test for less than 4.5 V between the serial data circuits listed below and ground: * Terminal 6 * Terminal 14 ‹› If greater than the specified range, test the serial data circuit for a short to voltage; refer to Testing the Serial Data Circuits for a Short to Voltage. 5. Ignition OFF for 60 seconds, test for greater than 100 ohm between the serial data circuits listed below and ground: * Terminal 6 * Terminal 14 ‹› If not the specified value, test the serial data circuit for a short to ground; refer to Testing the Serial Data Circuits for a Short to ground. 6. Test for 50-70 ohm between the serial data circuits terminal 6 and terminal 14. ‹› If less than 35 ohm, test for a short between the serial data circuits; refer to Testing the Serial Data Circuits for a Short between the Circuits. ‹› If 35-50 ohm there may be a third terminating resistor between the serial data circuits. This can happen if the incorrect control module is installed. Some control modules are available with and without the terminating resistors installed to reduce the need of terminating resistors in the wiring harness. ‹› If greater than 70 ohm but less than infinite, test the serial data circuit for an open/high resistance; refer to Testing the Serial Data Circuits for an Open/High Resistance. ‹› If infinite, test the serial data circuits between the DLC and the first connection to the serial data circuit for an open/high resistance. Testing the Serial Data Circuits for a Short to Voltage 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition ON, test for greater than 4.5 V between each serial data circuit at the control module connector that was just disconnected and ground. Page 4833 5. Remove the 2 brake caliper guide pin bolts. Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 6. Remove the brake caliper from the brake caliper mounting bracket. 7. Remove the brake pads (1) from the brake caliper mounting bracket (3). 8. Remove the brake pad retainers (2) from the brake caliper mounting bracket (3). Page 9988 Cruise Control: Testing and Inspection Cruise Control Indicator Malfunction Cruise Control Indicator Malfunction Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The cruise control switch contains an LED that illuminates to indicate the cruise control system has been switched ON. Voltage is applied through the ON/OFF switch to the LED when the switch is pressed. Pressing the switch again opens the switch and the lamp turns OFF. The body control module (BCM) monitors the cruise control indicator switch. Reference Information Schematic Reference Cruise Control Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Cruise Control Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification Ignition ON, observe the cruise control indicator while applying the cruise ON/OFF switch. The indicator should turn ON and OFF accordingly with the applied switch. Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the steering wheel controls switch - left. 2. Ignition OFF, test for less than 10 ohms between the ground circuit terminal 7 and ground. Page 3968 Locations Power Seat Switch: Locations Passenger Compartment/Roof Component Views Seat Components - Driver 1 - Seat Back Cover - Driver 2 - Heated Seat Element - Driver Back (KA1) 3 - Seat Back Cushion Pad - Driver 4 - Seat Recline Motor - Driver (1LZ) 5 - Seat Horizontal Motor - Driver (AG1 or 1LZ) 6 - Seat Rear Vertical Motor - Driver (AG1 or 1LZ) 7 - Heated Seat Control Module - Driver (KA1) 8 Seat Front Vertical Motor - Driver (AG1 or 1LZ) 9 - Seat Recline Switch - Driver (1LZ) 10 - Seat Adjuster Switch - Driver 11 - Seat Belt Switch - Driver 12 - Seat Cushion - Driver 13 - Heated Seat Element - Driver Cushion (KA1) 14 - Seat Cover - Driver Seat Components - Passenger Page 4053 Manual Shift Shaft and Seal Replacement Manual Shift Shaft and Seal Replacement Special Tools * J 45201 Cooler Line Seal Remover * J-46626 Seal Installer Removal Procedure 1. Remove the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair). 2. Remove the manual shaft and position switch assembly. Refer to Manual Shift Detent Lever with Shaft Position Switch Assembly Replacement ( See: Parking Pawl/Service and Repair/6T30/6T40/6T45 - Automatic Transmission). Page 9967 If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 5473 Fuel Injector 4 (LZ4 or LZE) Fuel Injector 5 (LY7) Page 6237 Crankshaft Position (CKP) Sensor (LAT or LE5 or LE9) Page 6363 Inflatable Restraint Steering Wheel Module Coil X3 Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 4395 10. Place a brass drift against the CV joint cage (1). 11. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 12. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 13. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 14. Repeat this process to remove all 6 of the balls. 15. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (2). At the same time, align the cage windows (3) with the lands of the outer race. 16. Lift out the cage (4) and the inner race. Page 6657 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 196 Page 6821 Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment 1. Ensure that the steering wheel is set in a straight ahead position. 2. Center the steering wheel position sensor prior to alignment. Refer to Steering Wheel Position Sensor Centering (See: Sensors and Switches Steering and Suspension/Sensors and Switches - Steering/Steering Angle Sensor/Service and Repair/Steering Wheel Position Sensor Centering) 3. Loosen the tie rod jam nut (5). 4. Adjust the toe to specification by turning the adjuster (6). Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the tie rod jam nut (5) to 68 Nm (50 lb ft). Page 6369 License Lamp Main Contactor Relay (HP7) X1 Page 10326 Page 4207 Shift Cable: Service and Repair 6T70/6T75 - Automatic Transmission Range Selector Lever Cable Replacement Range Selector Lever Cable Replacement Removal Procedure 1. Set the park brake and chock the wheels. 2. Disconnect the transmission range selector lever cable terminal (1) from the transmission manual shift lever pin (5). 3. Remove the retainer (2) from the transmission range selector lever cable. 4. Press the locking tabs inward in order to release the transmission range selector lever cable (3) from the cable bracket (4). 5. Remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). Page 7930 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Page 8461 Pedal Positioning Module: Diagrams Component Connector End Views Accessory Power Outlet - I/P Accessory Power Outlet - 110V AC (KV1) Diagrams DVD Player: Diagrams Component Connector End Views Digital Video Disc (DVD) Control Module X1 (SPO Accessory) (UJ5) Digital Video Disc (DVD) Control Module X2 (SPO Accessory) (UJ5) Page 7941 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. 2008 Model Year Buick Enclave, GMC Acadia and Saturn OUTLOOK Vehicles Only Note The seat mounted side impact airbag connection to the body harness is located at the forward edge of the seat, below the plastic trim. The connectors are yellow. The body harness wires are exposed - running forward in the vehicle, down through the carpet cutout in the floor. Page 9578 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. Page 3674 Page 6978 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Page 3476 Page 5783 Fuse Block - Underhood X4 Page 10450 Page 9619 Page 5694 X316 Inline Harness Connector End Views X316 DVD Signal Cable 3B to DVD Signal Cable 1B (SPO Accessory) (UJ5) X309 Inline Harness Connector End Views X309 Body Harness to Right Seat Inflatable Restraint Impact Module Jumper Harness and Pretensioner Page 3420 ‹› If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump Electrical Circuit Diagnosis). 2. Ignition OFF, all accessories OFF, install a CH 48027 - Pressure Gauge. Refer to Fuel Pressure Gauge Installation and Removal (See: Fuel Pressure Gauge Installation and Removal). 3. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and does not decrease more than 34 kPa (5 psi) in 1 minute. Circuit/System Testing Note: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel pressure gauge while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Install the J 37287 - Shut-off Adapter or the J 37287-FF Adapter between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 - Shut-off Adapter or the J 37287-FF - Adapter. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the CH 48027 - Gauge. 5. Command the fuel pump relay ON and then OFF with a scan tool. 6. Close the valve on the J 37287 - Shut-off Adapter or the J 37287-FF Adapter. 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injectors. ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with the CH 48027 - Gauge. The fuel pressure should not drop off during acceleration, cruise, or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Line Replacement - Chassis (See: Fuel Supply Line/Service and Repair) * Fuel Injector Replacement (See: Fuel Injector/Service and Repair) * Fuel Tank Fuel Pump Module Replacement (See: Service and Repair) Page 3733 1. Install the 3 input speed sensor seals (1). 2. Install the input speed sensor (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the input speed sensor bolt (2) M6 x 23 and tighten to 12 Nm (106 lb in). 4. Connect the input speed sensor electrical connector (1). 5. Install the transmission control valve body cover. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning/6T30/6T40/6T45 - Automatic Transmission). Page 7946 Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information 1. Submit a transaction using the table below. * The amount identified in the Net Item column should represent the actual cost of the woven polyester electrical tape, required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a customer satisfaction program that affects your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle. Page 3964 2. Install the TFP switch assembly onto the control valve body assembly and install the bolts. Tighten the control valve body bolts to 12 Nm (9 lb ft). 3. Install the transaxle case side cover. 4. Start the engine, warm up the transaxle, and check for leaks. 5. Inspect for proper fluid level. Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 6. Reset the TAP values. Refer to Transmission Adaptive Functions See: Description and Operation. Page 5539 Knock Sensor (KS) 1 (LZ4 or LZE or LY7) Knock Sensor (KS) 2 (LZ4 or LZE or LY7) Page 935 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Passenger Door Components Page 4650 Transmission Speed Sensor: Service and Repair 6T70/6T75 - Automatic Transmission Output Speed Sensor Replacement Output Speed Sensor Replacement Input Speed Sensor Replacement Input Speed Sensor Replacement Page 3641 Shift Solenoid: Service and Repair 6T70/6T75 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover Replacement). 2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3). 5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring (8) to the side. Spring will be released with the removal of the control valve body assembly. Page 7979 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. Page 3678 Communication Interface Module Replacement Communications Control Module: Service and Repair Communication Interface Module Replacement Communication Interface Module Replacement Page 5348 Page 5484 Generator Battery Temperature Sensor 1A and Generator Battery Temperature Sensor 1B (HP7) Page 10024 Page 6516 X300 Inline Harness Connector End Views X300 Body Harness to Driver Seat Harness Page 1555 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Page 5636 Accessory Power Outlet - Center Console Page 1269 6. Compress the power steering gear outlet hose clamp (1) and disconnect the power steering reservoir inlet hose (2) from the power steering gear outlet hose (3). 7. Remove the power steering reservoir inlet hose from the vehicle. Installation Procedure 1. Install the power steering reservoir inlet hose to the vehicle. 2. Compress the power steering gear outlet hose clamp (1) and connect the power steering gear outlet hose (3) to the power steering reservoir inlet hose (2). Page 4885 3. Remove the caps or plugs from the brake pipe fitting end and the brake hose end. 4. Install the brake hose to the brake hose body bracket. 5. Install the brake hose retainer (2) over the anti-rotation tabs of the brake hose (3). 6. Connect the brake pipe fitting (1) to the brake hose (3). 7. Use a backup wrench on the brake hose (3) and tighten the brake pipe fitting to 20 Nm (15 lb ft). 8. Ensure that the hose does not make contact with any part of the suspension. If the hose makes contact, remove the hose and correct the condition. 9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding). 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 11. Lower the vehicle. Page 4408 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the wheel bearing/hub mounting bolts (1) and tighten to 115 Nm (85 lb ft). Page 5696 X317 Inline Harness Connector End Views X317 DVD Signal Cable 3A to DVD Signal Cable 2A (SPO Accessory) (UJ5) Page 493 Pedal Positioning Sensor: Diagrams Component Connector End Views Brake Pedal Position (BPP) Sensor Page 8681 Front Bumper Bracket: Service and Repair Front Bumper Impact Bar Replacement Front Bumper Impact Bar Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning (See: Service Precautions/Technician Safety Information/Approved Equipment for Collision Repair Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Note: This panel is replaced at factory welds 3. Remove all related panels and components. 4. Repair as much of the damage as possible. Refer to Dimensions - Body (). 5. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (). Page 5460 Engine Coolant Temperature (ECT) Sensor (LY7) Page 9117 Page 7402 Installation Procedure 1. Position the backing plate and wheel bearing/hub assembly in the steering knuckle. Page 3475 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 4003 Important: Ensure the ignition key is in the RUN position. Do NOT attempt to remove the park lock cable with the key in any other position. 8. Using a screwdriver, release the cable from the ignition switch inhibitor by depressing the cable latch (1). 9. Remove the park lock cable from the inhibitor housing. 10. Attach a long piece of mechanics wire to the end of the park lock cable before removing the cable. The wire will assist with installation of the new cable. 11. Remove the park lock cable from the vehicle. 12. Remove the mechanics wire from the park lock cable. Installation Procedure 1. Attach the mechanics wire to the park lock cable in order to assist with installation of the cable. 2. Install the park lock cable to the vehicle. 3. Remove the mechanics wire from the park lock cable. 4. Ensure the shift lever is in the PARK position. 5. Ensure that the ignition key is in the RUN position. Page 7 Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Page 3108 Page 4796 6. Install the remaining CH-45101-100 - Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the CH-39544-KIT - Complete Torque Socket Set - 10 PCS, or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmarks the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Special Tools CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. Page 7685 4. Remove the white plug (1) and assure there is no debris in the drain tube and/or plug. If debris exists, pull from the drain tube (do NOT force back into evaporator case) and reinstall the plug. Important Do not get sealer on the heat shield, on the end of, or within the drain tube. 5. Mask off the areas (1, 2) by the HVAC drain using high-quality automotive tape. 6. Apply high tech seam sealer, Kent Industries P/N P10200*, to the front of dash area as shown in figure below. 7. Remove the high quality automotive tape and reposition the heat shield to its normal position. 8. Lower the vehicle. Let the vehicle run with A/C on. 9. Perform a final inspection for the A/C and verify that the system is draining properly. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information This product is currently available from Kent Industries (1-888-YES-KENT). Warranty Information Page 4678 2. Install the BPMV to the bracket (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the BPMV bolt (1) and tighten to 10 Nm (89 lb in). Page 4200 3. Install the transmission range selector lever cable (2) to the cable bracket. 4. Connect the transmission range selector lever cable terminal (1) to the transmission manual shift lever pin. 5. Check the range selector cable adjustment. Refer to Range Selector Lever Cable Adjustment (See: Adjustments/6T30/6T40/6T45 - Automatic Transmission). Range Selector Lever Cable Replacement Range Selector Lever Cable Replacement Removal Procedure 1. Set the park brake and chock the wheels. 2. Disconnect the transmission range selector lever cable terminal (1) from the transmission manual shift lever pin. 3. Press the locking tabs inward in order to release the transmission range selector lever cable (2) from the cable bracket. 4. Remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Page 313 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Locations Brake Fluid Pressure Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Steering - Front End Clunk/Rattle/Knock On Bumps Steering Gear: Customer Interest Steering - Front End Clunk/Rattle/Knock On Bumps TECHNICAL Bulletin No.: 06-02-32-007G Date: April 05, 2010 Subject: Clunk, Knock or Rattle Noise From Front of Vehicle While Driving or Turning Over Bumps at Low Speeds (Diagnose Noise and Perform Outlined Repair) Models: 2004-2006 Chevrolet Malibu Maxx 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn Aura Supercede: This bulletin is being revised to update the Parts Information for the bolt. Please discard Corporate Bulletin Number 06-02-32-007F (Section 02 - Steering). Condition 1 Some customers may comment on a clunk noise heard and felt in the steering wheel while driving at slow speeds and turning. The clunk noise may appear to be directly in front of the driver. Hitting a bump while turning can produce the clunk noise. Sometimes the noise may be duplicated when the vehicle is sitting still and the steering wheel is turned 90 degrees in either direction before initially centering the steering wheel. Cause 1 The clunk noise may be caused by a slip/stick condition between the inner and outer components of the intermediate shaft. Important Revised design intermediate shafts went into production in the 2009 model year and are the only design currently available through GMSPO since approximately September 2008. Since any model year vehicle could have had a second design shaft installed, it is critical to identify it before proceeding. The revised design intermediate shafts will NOT tolerate any type of lubricant per the following instructions. Adding lube to the second design shafts will cause a clunk noise in a very short period of time. Use the following pictures to identify which design of shaft you are servicing. Electric Assist Power Steering First Design - Bare Steel Tube (Lube OK) Page 327 Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 8712 3. Lower the vehicle. Page 9256 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 4652 Input Speed Sensor Seal Replacement Diagram Information and Instructions Seat Fan: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Page 3152 Knock Sensor (KS) 2 (LZ4 or LZE or LY7) Page 5188 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Page 9110 Page 5242 same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 6599 Page 5107 - Confirm that the vehicle responds with the appropriate lock and unlock function. - If Yes , the 2-way transmitter was in mode B. - Press and release the left side button twice within one second. The 2-way transmitter should enter second vehicle mode. - Use the "next available slot" method in the scan tool to program the 2-way transmitter to the 2-way RCDLR. Refer to Remote Control Door Lock Transmitter Programming in SI. - Both vehicle modes of the 2-way transmitter should now be coded to the vehicle. If No: The 2-way transmitter is not exhibiting the failure mode addressed by this bulletin. Refer to normal diagnostic procedures. Parts Information For part numbers, usage and availability of 2-way remote start, refer to the Accessory Parts Catalog or Corporate Bulletin Number 09-00-89-025A. Disclaimer Page 1766 Camshaft: Service and Repair Camshaft Position Exhaust Actuator Replacement Camshaft Position Exhaust Actuator Replacement Special Tools * EN-45059 - Angle Meter * EN-48749 - Timing Chain Retention Tool Kit * EN-48953 - Camshaft Actuator Locking Tool For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the camshaft cover. Refer to Camshaft Cover Replacement (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 2. Remove the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 3. Rotate the crankshaft clockwise and install the EN-48953 - locking tool (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the camshaft actuator retainer bolts and tighten to 10 Nm (89 lb in). 5. Loosen, but do not remove the exhaust camshaft actuator bolt. 6. Remove the EN-48953 - locking tool (1). 7. Clean the timing chain and gears with solvent. Note: Ensure the timing chain and the camshaft position actuators are marked for proper assembly. 8. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain. Body/Paint - 2010 Exterior Paint Codes Paint: All Technical Service Bulletins Body/Paint - 2010 Exterior Paint Codes INFORMATION Bulletin No.: 10-08-51-001 Date: January 05, 2010 Subject: Exterior Paint Codes Models: 2010 Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Locations Fuel Pump Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 4921 6. Remove the front cable retaining screw. 7. Remove the 2 front park brake cable plastic retainers from the body. 8. Remove the front floor console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 9. Remove the right rear park brake cable (1) from the crush bracket (5). 10. Remove the left rear park brake cable (2) from the crush bracket (5). Page 4728 Installation Procedure 1. Install the brake caliper to the brake caliper bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the brake caliper guide pin bolts (2) and tighten to 35 Nm (26 lb ft). 3. Remove the caps or plugs from the brake caliper opening and the brake hose. Note: Do not reuse the copper brake hose gaskets. 4. Install NEW copper brake hose gaskets (2) to the brake hose-to-caliper bolt (1) and to the brake hose (3). 5. Install the brake hose and the brake hose-to-brake caliper bolt to the brake caliper and tighten the bolt to 50 Nm (37 lb ft). 6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding). Page 10247 and Repair). 8. Lower the vehicle. 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Testing and Inspection). Page 5202 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 9729 Seat Components - Passenger 1 - Seat Back Cover - Passenger 2 - Heated Seat Element - Passenger Back (KA1) 3 - Seat Back Cushion Pad - Passenger 4 - Seat Belt Switch - Passenger 5 - Seat Horizontal Motor - Passenger (1LZ) 6 - Seat Rear Vertical Motor - Passenger (1LZ) 7 - Heated Seat Control Module - Passenger (KA1) 8 - Seat Front Vertical Motor - Passenger (1LZ) 9 - Heated Seat Switch - Passenger (KA1) 10 - Seat Adjuster Switch - Passenger (1LZ) 11 - Inflatable Restraint Front Passenger Presence System (PPS) Module 12 - Seat Cushion - Passenger 13 - Heated Seat Element - Passenger Cushion (KA1) 14 - Seat Cover - Passenger Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 8480 Audio Amplifier X2 (UQ3) Locations Brake Fluid Pressure Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Diagrams Fuel Tank Unit: Diagrams Component Connector End Views Fuel Pump and Sender Assembly Page 2035 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) enables the fuel pump relay when the ignition switch is turned ON. The ECM will disable the fuel pump relay within 2 seconds unless the ECM detects ignition reference pulses. The ECM continues to enable the fuel pump relay as long as ignition reference pulses are detected. The ECM disables the fuel pump relay within 2 seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Powertrain Management/Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH 48027 - Digital Pressure Gauge * J 37287 - Fuel Line Shut-off Adapter * J 37287-FF - Fuel Line Shut-off Adapters, if equipped with an LE9 engine Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test, review the User Manual CH 48027-5 for Safety Information Instructions. 1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. Page 5152 Page 6480 Automatic Transmission Output Shaft Speed (OSS) Sensor (MH2 or MH8) Page 2314 - Select Fuel Composition Reset (F1). - The first parameter is "Fuel Alcohol Content" displayed as a percentage. If the Fuel Alcohol Content percentage is above 25%, this is the probable cause of DTC P0172. - From this screen the "Fuel Alcohol Content" can be reset to zero by pressing the lower right Tech 2(R) button. It will then display 0% when it's reset. Finally, reprogram the PCM with the latest calibration. This will correct for the PCM alcohol calculations. Note The PCM must be reset from this screen. It does not reset to zero when the PCM is reprogrammed. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 7446 Note: Align the left air outlet duct to the left air outlet duct extension. 1. Install the left air outlet duct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the left air outlet duct screws and tighten to 2.5 Nm (22 lb in). 3. Connect the wire harness clip at the left air outlet duct. 4. Install the I/P assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Instrument Panel Outer Air Outlet Upper Duct Replacement - Right Side Instrument Panel Outer Air Outlet Upper Duct Replacement - Right Side Removal Procedure 1. Remove the instrument panel (I/P) assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). 2. Remove the right hand side window defogger duct screws. Page 8017 Page 5908 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 6567 Page 5631 A/C Compressor Clutch A/C Refrigerant Pressure Sensor Page 347 Page 6401 Seat Horizontal Motor - Driver (AG1 or LTZ) Seat Horizontal Motor - Passenger (LTZ) Page 9495 Page 9487 Page 6626 Page 9389 Head Rest: Service and Repair Rear Seat Head Restraint Replacement Rear Seat Head Restraint Replacement Page 5088 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the generator. * Tighten the bolts to 50 Nm (37 lb ft). * Tighten the nuts to 30 Nm (22 lb ft). 2. Install the generator electrical connections. 3. Install the drive belt. Refer to Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 4. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Page 10415 Page 9456 Seat Cushion: Service and Repair Rear Seat Cushion Cover and Pad Replacement Rear Seat Cushion Cover and Pad Replacement Page 1125 1. Ensure that the steering wheel is set in a straight ahead position. 2. Center the steering wheel position sensor prior to alignment. Refer to Steering Wheel Position Sensor Centering (See: Sensors and Switches/Sensors and Switches - Steering and Suspension/Sensors and Switches Steering/Steering Angle Sensor/Service and Repair/Steering Wheel Position Sensor Centering) 3. Loosen the tie rod jam nut (5). 4. Adjust the toe to specification by turning the adjuster (6). Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the tie rod jam nut (5) to 68 Nm (50 lb ft). Rear Camber Adjustment Rear Camber Adjustment 1. Loosen the inner lower control arm cam bolt nuts. 2. Rotate the cam bolts to the required camber specification setting. Refer to Wheel Alignment Measurement (See: Wheel Alignment Measurement ). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Maintain the camber setting while tightening the cam bolt nuts. Tighten the inner lower control arm (front) bolt nut to 110 Nm (81 lb ft). Note: Check the toe setting AFTER changing camber or caster. Page 10012 Page 6581 Fuse Block - Underhood X5 (Battery Positive Cable) (without NVH) Fuse Block - Underhood X6 (Battery Positive Cable) Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 10639 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 6404 Seat Vertical Motor - Driver (without LTZ and AG1) Secondary Air Injection (AIR) Pump (NU6) Page 8091 10. Mount the seat belt pretensioner (1) in the SIR deployment fixture (3) with the open end facing up using the following mounting method. * Adjust and secure the J 39401-B arms (4) to the deployment fixture, with the short slotted portions of the arms standing vertically and facing toward the center of the deployment fixture. * To mount, use the proper size bolt (2) and nut (5) with washers in order to secure the seat belt pretensioner (1) to the deployment fixture brackets. * Securely tighten all fasteners prior to deployment. 11. Inspect the J 38826 and the appropriate pigtail adapter for damage. Replace as needed. 12. Short the 2 SIR deployment harness (1) leads together using 1 banana plug seated into the other. Locations Brake Fluid Pressure Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 6910 9. Install the engine lift bracket (2) and bolts (1). Tighten the bolts to 50 Nm (37 lb ft). 10. Clean any excess power steering fluid from the vehicle and remove the drain pans. 11. Install the drive belt idler pulley. Refer to Drive Belt Idler Pulley Replacement (). 12. Install the power steering pump pulley. Refer to Power Steering Pump Pulley Replacement (See: Power Steering Pump/Service and Repair/Power Steering Pump Pulley Replacement). 13. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). Page 7634 9. Install the suction line to the dash clip. 10. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 11. Leak test the fittings using the J 39400-A. 12. Install the surge tank to the surge tank bracket. Page 2633 2. Measure from the same end as earlier, and slide the current sensor to that measurement on the negative battery cable. 3. Install the battery negative cable. Refer to Battery Negative Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). Page 6508 X130 Engine Harness to Fuel Injector Harness (LY7) Page 2880 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors Tyco/AMP Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 9263 The primary exterior body paint codes on the SPID label may be missing on some 2010 vehicles. Above is a chart with the primary exterior body colors for your reference. Disclaimer Page 6037 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Delphi Connectors Delphi Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Fuse Block - Underhood Relay Box: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 1839 6. Install the EN-43649-10 - adaptor set (1) to the front and rear of the cylinder head. 7. Install the cross bars and locks (2) of the EN-43649 - compressor to the valve spring compressor adaptors. 8. Remove the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 9. Install an air hose adapter into the spark plug hole. 10. Attach an air hose to the adapter and pressurize the cylinder to 690 kPa (100 psi). 11. Compress the valve spring using the valve spring compressor (3). 12. Remove the valve spring keepers (1). 13. Remove the valve spring (3) and retainer (2). Electrical - Various Electrical Concerns/False Messages Door Position Switch: Customer Interest Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Locations Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 5668 Brake Fluid Level Switch Brake Master Cylinder Pressure Sensor (LAT) Page 9344 5. Pull downward on the front edge of the sunroof water gutter to allow standing bosses to clear the cross-member. Slide the sunroof water gutter rearward to release the retaining tabs from the slots on the track assembly. 6. Remove the sunroof water gutter from the track assembly. Installation Procedure 1. Position the sunroof water gutter to the sunroof window track assembly. 2. Pull downward on the front edge of the sunroof water gutter to allow standing bosses to clear the cross-member. Seat the tabs on the sunroof water gutter into the slots in the track assembly, and push the sunroof water gutter forward until the tabs lock into place. 3. Ensure that all tabs are secured. Page 3121 Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If reinstalling the original sensor, or if installing a NEW sensor without a sealer, coat the threads with sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor (1) to the thermostat housing and tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Locations Pressure Regulating Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 5519 Ignition Coil 6 (LY7) Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Locations Backup Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 2193 1. Install a NEW thermostat cover O-ring seal into the recess groove. 2. Install the thermostat, if necessary. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the thermostat cover bolts, if necessary. Tighten the bolts to 10 Nm (89 lb in). 4. Install a NEW thermostat housing to engine gasket onto the thermostat housing. 5. Load the thermostat housing assembly into position. Note: The water feed pipe seals can be lightly lubricated with coolant to aid during installation. 6. Install NEW O-ring seals onto the water feed pipe. Note: Lubricate the O-rings with coolant ONLY. 7. Install the water feed pipe into the thermostat housing aligning locator tab. 8. Align the water pipe to water pump. Page 4546 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Component Location Component Location Component Locations 1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear Support Assembly 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid Pump Drive Link Assembly 12 - Park Pawl Page 8474 Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Replacement Brake Pedal Position Sensor Replacement Page 7442 Air Duct: Service and Repair Instrument Panel Center Air Outlet Duct Replacement Instrument Panel Center Air Outlet Duct Replacement Page 5485 Generator Battery Temperature Sensor 2A and Generator Battery Temperature Sensor 2B (HP7) Generator Battery Temperature Sensor 3A and Generator Battery Temperature Sensor 3B (HP7) Page 9696 crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. Page 1878 13. Remove the floor jacks from under the oil pan. 14. Shake the powertrain vigorously from front to rear and allow the powertrain to settle. 15. Raise the vehicle. 16. Tighten the rear transaxle mount through bolt (1). Tighten the bolt to 100 Nm (74 lb ft). 17. Tighten the front transaxle mount through bolt (1). Tighten the bolt to 100 Nm (74 lb ft). 18. Lower the vehicle. 19. Install the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair). 20. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). Page 117 Heated Seat Control Module - Passenger X1 (KA1) Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Page 2296 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 6056 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 6038 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 9941 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 5172 Page 8112 Seat Belt Buckle Switch: Diagrams Component Connector End Views Seat Belt Switch - Driver Seat Belt Switch - Passenger Page 9835 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Extension Replacement Air Inlet Grille Panel Extension Replacement Page 2619 1. Install the MAF/IAT sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1) and tighten to 2.5 Nm (22 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor (2). Page 6312 Generator Battery Disconnect Control Module X2 (LAT) Page 4302 Transmission Speed Sensor: Connector Views Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Output Shaft Speed (OSS) Sensor (MH2 or MH8) Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 4543 1 - Control Solenoid Valve Assembly (with Transmission Control Module) Page 3616 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Remove the automatic transaxle control assembly. 2. Disconnect the Shift Lock Control Solenoid connector from the solenoid. 3. Using a flat-blade screwdriver or similar tool pry the solenoid off of the ball-sockets on the solenoid plunger and solenoid body. Page 3446 7. Loosen the fuel fill pipe hose clamp (3) at the fuel tank. 8. Separate the fuel fill pipe hose from the fuel tank. 9. Disconnect the fuel tank fill EVAP pipe quick connect fitting (2) from the fuel tank vent pipe (1). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 10. Remove the fuel tank fill pipe. Installation Procedure 1. Install the fuel tank fill pipe. 2. Install the fuel fill pipe hose to the fuel tank. 3. Connect the fuel tank fill EVAP pipe quick connect fitting (2) to the fuel tank vent pipe (1). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the fuel fill pipe hose clamp (3) at the fuel tank and tighten the clamp to 4 Nm (35 lb in). TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 2211 8. Remove the lower right HO2S electrical connector CPA retainer (1). 9. Disconnect the rear HO2S electrical connector from the engine wiring harness electrical connector (2). 10. Remove the lower left HO2S CPA retainer (3). 11. Disconnect the front engine wiring harness electrical connector (1) from the HO2S electrical connector. Page 5647 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (ME7 or MN5) Page 9426 Seat Back: Service and Repair Rear Seat Back Side Cushion Cover Replacement Rear Seat Back Side Cushion Cover Replacement Page 5553 Park/Turn Signal Lamp - Left Page 9103 Page 2881 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 1107 Alignment: Description and Operation Thrust Angles Description Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. If the thrust angle is not set properly the vehicle may "dog track", the steering wheel may not be centered or it could be perceived as a bent axle. Thrust angle can be checked during a wheel alignment. Positive thrust angle means the thrust line is pointing to the right hand side (RHS) of the vehicle. Negative thrust angle means the thrust line is pointing to the left hand side (LHS) of the vehicle. If the thrust angle is out of specification, moving the axle to body relationship will change the thrust angle reading. If the vehicle is out in the Positive (+) direction-moving the RHS forward and/or LHS rearward will move the thrust angle towards zero degrees. If the vehicle is out in the Negative (-) direction-moving the RHS rearward and/or LHS forward will move the thrust angle towards zero degrees. Page 5939 "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN(s) 19118426 and 20968489 will not be eligible for RIM management. * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Service Procedure Replace Wire Harness Connector 2010 Chevrolet Malibu and 2010 Pontiac G6 Tools Required - J 38125-7 Crimp Tool - J 38125-6 Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Seat shown out-of-vehicle for illustration purposed Page 9651 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 6686 Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information 1. Submit a transaction using the table below. * The amount identified in the Net Item column should represent the actual cost of the woven polyester electrical tape, required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a customer satisfaction program that affects your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle. Locations Camshaft Position Sensor: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch Page 2135 5. Reposition the heater inlet hose clamp at the engine using the J 38185. 6. Remove the heater inlet hose from the engine. Installation Procedure 1. Install the heater inlet hose to the engine. 2. Reposition the heater inlet hose clamp at the engine using the J 38185. Page 3060 Page 5745 Fuse Block - Underhood X1 Page 6568 Page 1585 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Locations Throttle Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left Side of the Instrument Panel Components (1 of 2) 1 - Brake Pedal Position (BPP) Sensor 2 - Accelerator Pedal Position (APP) Sensor 3 - Accelerator Pedal 4 - Brake Pedal Page 5472 Fuel Injector 4 (LAT or LE5 or LE9) Fuel Injector 4 (LY7) Page 5565 Component Connector End Views Seat Adjuster Switch - Driver (LTZ) Seat Adjuster Switch - Driver (AG1) Page 1376 Fuses ................................................................................................................................................... ......................................................................... Usage Fuse 1 .................................................................................................................................................. .......................................... Air Conditioner Clutch Fuse 2 ................................................................... ................................................................................................................... Electronic Throttle Control Fuse 3 .................................................................................................................................................. ................................................................ Not Used Fuse 4 ................................................................. ................................................................................................ Transmission Control Module Ignition 1 Fuse 5 ............................................................................................................................................... ...................................... Mass Airflow Sensor (LY7) Page 1027 Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 8. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. Page 2861 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Locations Hood Sensor/Switch (For Alarm): Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (2 of 2) 1 - Hood Ajar Switch (AP3) Page 838 5. Remove the fuel injector wiring harness clips (1) from the fuel rail tabs. 6. Disconnect the fuel injector wiring harness electrical connector (2) from the number 3 fuel injector. 7. Squeeze tabs and slide the MAP sensor (1) upward. Installation Procedure Page 630 Repair/Cooling System Draining and Filling). Page 9975 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 9043 Rear Compartment Trim Panel Replacement Rear Compartment Trim Panel Replacement Page 9959 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Service and Repair Air Bag Deactivation Indicator: Service and Repair Inflatable Restraint Instrument Panel Module Indicator Replacement Page 5979 Page 5700 X413 Inline Harness Connector End Views X413 Fuel Sender Harness to Body Harness Page 6201 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 2770 Engine Control Module: Description and Operation Engine Control Module Description The engine control module (ECM) interacts with many emission related components and systems, and monitors the emission related components and systems for deterioration. OBD II diagnostics monitor the system performance and a diagnostic trouble code (DTC) sets if the system performance degrades. The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type. A DTC is ranked as a Type A or Type B if the DTC is emissions related. Type C is a non-emissions related DTC. The ECM is in the engine compartment. The ECM is the control center of the engine controls system. The ECM controls the following components: * The fuel injection system * The ignition system * The emission control systems * The on-board diagnostics * The A/C and fan systems * The throttle actuation control (TAC) system The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect the vehicle performance and the emissions. The ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational problems and alert the driver via the MIL. When the ECM detects a malfunction, the ECM stores a DTC. The condition area is identified by the particular DTC that is set. This aids the technician in making repairs. ECM Function The engine control module (ECM) can supply 5 V or 12 V to the various sensors or switches. This is done through pull-up resistors to the regulated power supplies within the ECM. In some cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is too low. Therefore, a DMM with at least 10 Mohm input impedance is required in order to ensure accurate voltage readings. The ECM controls the output circuits by controlling the ground or the power feed circuit through the transistors or a device called an output driver module. EEPROM The electronically erasable programmable read only memory (EEPROM) is a permanent memory that is physically part of the engine control module (ECM). The EEPROM contains program and calibration information that the ECM needs in order to control the powertrain operation. Special equipment, as well as the correct program and calibration for the vehicle, are required in order to reprogram the ECM. Data Link Connector (DLC) The data link connector (DLC) is a 16-pin connector that provides the technician a means of accessing serial data for aid in the diagnosis. This connector allows the technician to use a scan tool in order to monitor the various serial data parameters, and display the DTC information. The DLC is located inside of the drivers compartment, underneath the dash. Malfunction Indicator Lamp (MIL) The malfunction indicator lamp (MIL) is inside of the instrument panel cluster (IPC). The MIL is controlled by the engine control module (ECM) and illuminates when the ECM detects a condition that affects the vehicle emissions. ECM Service Precautions The engine control module (ECM), by design, can withstand the normal current draws that are associated with the vehicle operations. However, care must be used in order to avoid overloading any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the ECM circuits unless the diagnostic procedure instructs you to do so. These circuits should only be tested with a DMM. Emissions Diagnosis For State I/M Programs This OBD II equipped vehicle is designed to diagnose any conditions that could lead to excessive levels of the following emissions: * Hydrocarbons (HC) * Carbon monoxide (CO) * Oxides of nitrogen (NOx) Interior - Rear Shelf Foam Seal Is Loose Sunroof / Moonroof Module: Diagrams Component Connector End Views Sunroof Control Module (CF5) Page 8899 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Water Deflector Replacement Air Inlet Grille Panel Water Deflector Replacement Page 7497 Page 3726 1 - Control Valve Body Cover Assembly 2 - Transmission Fluid Level Indicator Assembly 3 - Fluid Level Indicator Tube - Model Dependent 4 - Fluid Level Indicator Tube Seal - Model Dependent 5 Control Valve Body Cover Assembly Gasket 6 - Control Valve Body Cover Stud 7 - Control Valve Body Cover Bolt 8 - Control Valve Body Bolt 9 - Control Valve Body Bolt 10 - Control Valve Body Cover Wiring Connector Hole Seal 11 - Control Solenoid Valve Spring 12 - Control Valve Body Bolt 13 - Control Valve Body Bolt 14 - Control Valve Body Bolt 15 - Control Solenoid (w/Body and TCM) Valve Assembly 16 - Control Solenoid (w/Body and TCM) Filter Plate Assembly 17 - Manual Shaft Detent Assembly 18 - Control Valve Body Assembly 19 - A/Trans Output Speed Sensor Assembly 20 - A/Trans Output Speed Sensor Bolt 21 - A/Trans Case Assembly 22 - Torque Converter Housing Outer Seal 23 - Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly 24 Front Differential Drive Pinion Gear Lube Tube Page 852 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY7 or LZ4 or LZE) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LY7 or LZ4 or LZE) Page 6605 Fuse Block - Underhood Bottom View Page 6348 Ignition Coil 6 (LY7) Page 3842 Shift Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH2) Page 5180 Page 7212 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 8. Lower the vehicle. Page 4123 4. Remove the shift lock control solenoid. Installation Procedure 1. Route the shift lock control solenoid through the opening in the front of the control assembly. Page 191 Page 5175 Page 5076 13. Position the steering column harness package lead to the UBEC and tighten the integral bolt (4). Tighten the bolt to 5 Nm (44 lb in). 14. Position the positive battery cable to the battery. 15. Position positive battery cable lead (4) to the UBEC and tighten the integral bolt (5). Tighten the bolt to 5 Nm (44 lb in). 16. Install the UBEC cover. 17. Install the battery. Refer to Battery Replacement (See: Service and Repair/Removal and Replacement). Page 6166 Page 4380 Note: Place a towel in the vise before inserting the halfshaft. 1. Mount the halfshaft into a vise. 2. Install the new small eared clamp (2) on the neck of the outboard seal (1). Do not crimp. 3. Slide the outboard seal (1) onto the halfshaft bar and position the neck of the outboard seal (1) in the seal groove on the halfshaft bar. The largest groove below the sight groove on the halfshaft bar is the seal groove (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Crimp the eared clamp (1) using the J 35910, a breaker bar, and a torque wrench. Tighten the eared clamp to 136 Nm (100 lb ft). 5. Check the gap dimension, continue tightening until the gap dimension is reached. Page 8262 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 9559 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Page 6680 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. Page 9903 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Page 4746 4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper (5). Discard the boot seal. 5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal. 6. Remove the bleeder valve cap (6). 7. Remove the bleeder valve (7). Note: Do not use abrasives to clean the brake caliper piston. 8. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 10. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 11. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air. 12. Inspect the caliper piston for cracks, scoring, and/or damage to the plating. Replace the caliper piston if any of these conditions exist. 13. Inspect the caliper mounting holes for cracks, scoring, pitting, rust and/or excessive corrosion. Replace the caliper assembly if any of these conditions exist. Assembly Procedure Page 7264 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Page 4056 Manual Shift Shaft and Seal Replacement Manual Shift Shaft and Seal Replacement Page 2297 Body Control Module: Diagrams Component Connector End Views Body Control Module (BCM) X1 Page 7309 11. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. Ensure that the valve stem (1) is at the 7 o'clock position. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem (1) is at the 7 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Exploded Views Shift Solenoid: Exploded Views 6T30/6T40/6T45 - Automatic Transmission Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly Page 4801 Specification - Front * Brake rotor minimum allowable thickness after refinishing: 23 mm (0.906 in) * Brake rotor discard thickness: 22.8 mm (0.898 in) Specification - Rear * Brake rotor minimum allowable thickness after refinishing: 12.0 mm (0.472 in) * Brake rotor discard thickness: 11.8 mm (0.465 in) 5. If the lowest thickness measurement of the brake rotor is above the minimum allowable thickness after refinishing specification, the rotor may be able to be refinished, depending upon surface and wear conditions which may be present. 6. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable thickness after refinishing specification, the rotor may not be refinished. 7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness specification, the rotor requires replacement. Brake Rotor Thickness Variation Measurement Brake Rotor Thickness Variation Measurement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: Any disc brake rotor that exhibits thickness variation exceeding the maximum acceptable level must be refinished or replaced. Thickness variation exceeding the maximum acceptable level can cause brake pulsation. 1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with the brake pads. Refer to Front Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Removal and Replacement/Front Disc Brake Pads Replacement) and/or Rear Disc Brake Pads Replacement (See: Brake Pad/Service and Repair/Removal and Replacement/Rear Disc Brake Pads Replacement). 2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 3. Using a micrometer calibrated in thousandths-of-a-millimeter, or ten-thousandths-of-an-inch, measure and record the thickness of the brake rotor at 4 or more points, evenly spaced around the rotor. Ensure that the measurements are only taken within the friction surfaces and that the micrometer is positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in), for each measurement. 4. Calculate the difference between the highest and lowest thickness measurements recorded to obtain the amount of thickness variation. 5. Compare the thickness variation measurement to the following specification: Brake rotor maximum allowable thickness variation: 0.025 mm (0.001 in) Note: Whenever a brake rotor is refinished or replaced, the assembled lateral runout (LRO) of the rotor must be measured to ensure optimum performance of the disc brakes. 6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires refinishing or replacement. Locations Fluid Pressure Sensor/Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 9548 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Page 9733 Heated Seat Control Module - Passenger X2 (KA1) Page 4071 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (ME7 or MN5) Page 4588 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 4557 Shift Solenoid: Service and Repair 6T70/6T75 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover Replacement). 2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3). 5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring (8) to the side. Spring will be released with the removal of the control valve body assembly. Page 1391 Page 5759 Diagrams Entertainment System Control Module: Diagrams Electrical Center Identification Views Fuse Holder - Digital Video Disc (DVD) Control Module (UJ5) Page 4169 Automatic Transmission Manual Shift Switch - Right (KB7) Page 8285 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 1533 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 8. Lower the vehicle. Page 8741 Door Latch - Right Rear Page 3853 4-3 Shift Solenoid (SS) Valve (ME7 or MN5) Control Solenoid Valve Assembly (MH2) Page 6768 "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN(s) 19118426 and 20968489 will not be eligible for RIM management. * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Service Procedure Replace Wire Harness Connector 2010 Chevrolet Malibu and 2010 Pontiac G6 Tools Required - J 38125-7 Crimp Tool - J 38125-6 Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Seat shown out-of-vehicle for illustration purposed Page 9974 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Page 6408 Speaker - Left Front (UQA) Locations Transmission Control System Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 4072 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transaxle case side cover. 2. Remove the TFP switch assembly bolts. 3. Remove the TFP switch assembly from the control valve body assembly. The TFP switch O-rings are reusable if not damaged and should remain with the switch assembly. Installation Procedure 1. Inspect the TFP switch assembly in order to verify the condition and correct location of the pressure switch O-rings. If necessary, replace the O-rings. Caution: Refer to Fastener Caution Page 3489 3. Remove the throttle body bolts. 4. Remove the throttle body. 5. Inspect the throttle body gasket, and replace if necessary. Installation Procedure 1. Install the throttle body. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the throttle body bolts and tighten to 10 Nm (89 lb in). Page 1036 85 - Transaxle Oil Filter Assembly 86 - Oil Level Control Valve 87 - Transaxle Bottom Pan Gasket 88 - Transaxle Oil Pan 89 - Chip Collector Magnet 120 - Chip Collector Magnet (Some Models) 126 - Side Cover Stud 127 - Transmission Wiring Harness Assembly (Some Models) 128 - Electrical Connector Retaining Bracket (Some Models) Case and Associated Parts - L4 Hybrid 1 - Side Cover (Structural) 2 - Axle Oil Seal 3 - Side Cover Bolt 4 - Side Cover Stud 5 - Side Cover Gasket 6 - Side Cover Oil Level Control Gasket 7 - Thrust Washer (Side Cover to Driven Sprocket) 8 - Oil Pump Bolt 9 - Oil Pump Bolt 10 - Transaxle Oil Pump Assembly 11 - Transaxle Wiring Assembly 12 - TFP Manual Valve Position Switch Assembly Bolt 13 - TFP Manual Valve Position Switch Assembly 15 - Wiring Harness Bracket Bolt/Input Speed Sensor Bolt 51 - Transaxle Case 52 - Vent Cap 55 - Torque Converter Assembly 61 - Output Speed Sensor Stud 62 - Output Shaft Speed Sensor 63 - O-Ring Seal (Output Speed Sensor) Service and Repair Trunk / Liftgate Hinge: Service and Repair Rear Compartment Lid Hinge Replacement Page 7940 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. Page 7788 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Page 3097 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). 2. Ensure that the location measurement of the battery current sensor was recorded for reference during installation. 3. Squeeze the ground ends of the negative battery cable together and remove the sensor (1) from the cable. Installation Procedure Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 1. Install the battery current sensor (1) by passing the ground ends of the negative battery cable through the sensor. Locations Pedal Positioning Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 4623 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement Special Tools J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. Warning Locations Alarm Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 573 Brake Booster Vacuum Sensor: Diagrams Component Connector End Views Brake Booster Vacuum Sensor (LAT) Page 2866 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Locations Camshaft Position Sensor: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch Page 3948 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the three retaining ring ears are seen from inside the fitting and that the retaining ring moves freely in the fitting slots. 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. Locations Starter Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 4788 10. Install the remaining CH-45101-100 - Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 11. Using the CH-39544-KIT - Complete Torque Socket Set - 10 PCS, or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 12. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 14. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Page 4142 Control Solenoid Valve Assembly (MH8) Page 1165 Caution: Do not coat spark plug threads with anti-seize compound. If anti-seize compound is used and spark plugs are over-torqued, damage to the cylinder head threads may result. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the spark plugs and tighten the plugs to 20 Nm (15 lb ft. The spark plug gap is 1.0 mm (0.040 in). 2. Install the ignition coil(s). Refer to Ignition Coil Replacement (See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair). Page 5630 2-3 Shift Solenoid (SS) Valve (ME7 or MN5) 4-3 Shift Solenoid (SS) Valve (ME7 or MN5) Page 4099 1 - Control Valve Body Cover Bolt 2 - Control Valve Body Cover Assembly 3 - Control Valve Body Cover Gasket 4 - Control Valve Body Bolt 5 - Control Valve Body Cover Hole Seal 6 - Control Solenoid Valve Heat Sink Bolt 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Control Valve Body Filter Plate Assembly 9 - Control Valve Body Bolt 10 - Control Valve Body Bolt 11 Control Valve Body Assembly 12 - Control Valve Body Spacer Plate Assembly 13 - A/Trans Fluid Level Control Valve 14 - A/Trans Fluid Level Control Valve Gasket 15 - A/Trans Output Speed Sensor Bolt 16 - A/Trans Output Speed Sensor Assembly 17 - Manual Shaft Detent Spring Bolt 18 - Manual Shaft Detent Lever Spring Assembly 19 - A/Trans Input Speed Sensor Assembly 20 A/Trans Input Speed Sensor Assembly O-Ring Seal 21 - A/Trans Input Speed Sensor Bolt 22 - Fill Cap 23 - Fill Cap Seal 24 - Torque Converter Housing Gasket Locations Trunk / Liftgate Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 2343 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 4621 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Service and Repair Parking Brake Lever: Service and Repair Parking Brake Lever Pedal Assembly Replacement Removal Procedure The automatic adjustment park brake pedal assembly and the front park brake cable are serviced as a unit. The front park brake cable has no threads and is not adjustable. 1. Remove left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 2. Remove the left front carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Removal and Replacement/Front Side Door Opening Floor Carpet Retainer Replacement). 3. Remove the 3 park brake pedal assembly nuts (1, 2, 3). 4. Pull the carpet back to expose the front park brake cable. 5. Disconnect the electrical connector from the park brake warning lamp switch. Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Front and Right Side of the Engine Components (LY7) Page 6683 3. Disconnect the seat to body harness connector (1). Disconnect the seat airbag connector (2). Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing into the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Slide the conduit away on the seat airbag harness and remove just enough tape on the body harness to access the wires to install the terminals and seals. Note Use caution when stripping insulation. Take care not to cut through the wire strands. 5. Slide the wire seals onto all four leads back enough to enable removal of the insulation. Install the blue seals (1) on the body harness and the white seals (2) on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Page 9250 Page 1051 Transmission Speed Sensor: Service and Repair 6T70/6T75 - Automatic Transmission Output Speed Sensor Replacement Output Speed Sensor Replacement Input Speed Sensor Replacement Input Speed Sensor Replacement Page 4294 64 - Band Anchor Pin (Lo/Reverse) 65 - Oil Level Control Plug 81 - Tube Assembly Bolt/Bottom Pan Bolt 84 - Transaxle Oil Filter Seal 85 - Transaxle Oil Filter Assembly 86 - Oil Level Control Valve 87 - Transaxle Bottom Pan Gasket 88 - Transaxle Oil Pan 89 - Chip Collector Magnet 120 Chip Collector Magnet (Some Models) 126 - Side Cover Stud 130 - A/Trans Auxiliary Fluid Pump Assembly 131 - Auxiliary Trans Fluid Pump Bolts 132 - Auxiliary Pump Pipe Bolts Component Location Component Location Transmission Major Components 1 - TFP Manual Valve Position Switch Assembly 2 - Control Valve Body Assembly Page 2663 Page 1275 11. Remove the power steering gear inlet hose bolt (1) and disconnect the power steering gear inlet hose (2) from the steering gear. 12. Remove the power steering gear inlet hose from the vehicle. Caution: Clean the power steering gear inlet and outlet ports thoroughly of any debris. Failure to do so could result in contamination and damage to the power steering system components. 13. Install the J 44586 - remover/installer (2) to the steering gear oil seal (1). Page 5001 1. Install the park brake warning lamp switch (2) to the park brake pedal assembly (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch screw (3) and tighten to 2 Nm (18 lb in). 3. Connect the electrical connector to the park brake warning lamp switch. 4. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 5. Check the operation of the park brake warning lamp switch. Page 3219 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). 6. Remove the alignment tool. Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 7. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Locations Traction Control Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 9633 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Page 3072 Page 5497 Heated Seat Control Module - Passenger X1 (KA1) Page 1900 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Place a drain pan under the oil drain plug. 3. Remove the oil pan drain plug. 4. Allow the oil to drain completely. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the oil pan drain plug and tighten to 25 Nm (18 lb ft). 6. Lower the vehicle. Note: DO NOT use an open end wrench on the hex on top of the oil filter cap. 7. use an oil filter wrench on the outside diameter of the oil filter cap. 8. Remove the oil filter cap and filter. 9. Remove the filter from the cap. Installation Procedure Page 9671 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 9566 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. Page 6238 Crankshaft Position (CKP) Sensor (LY7) Crankshaft Position (CKP) Sensor (LZ4 or LZE) Page 8241 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Service and Repair Knee Diverter: Service and Repair Driver Knee Bolster Panel Replacement Page 10169 Customer TPMS Information Page 9665 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 4836 Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 1. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire (1), or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Front Brake Caliper Replacement (See: Front Brake Caliper Replacement). 2. Remove the brake pads (2) from the brake caliper bracket. 3. Remove the brake pad retainers (2) from the brake caliper bracket. 4. If reusing the bracket, thoroughly clean the pad hardware mating surfaces (1) of the caliper bracket, of any debris and corrosion. 5. Inspect the disc brake pad retainers (2) for the following: * Bent mounting tabs * Excessive corrosion * Looseness at the brake caliper mounting bracket * Looseness at the disc brake pads Page 6970 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Page 6253 Door Latch - Passenger Page 5139 Page 9183 Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 5746 Service and Repair Fluid Filter - A/T: Service and Repair Automatic Transmission Fluid Filter and Seal Replacement Removal Procedure Warning Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. 1. Position the vehicle on a hoist and raise the vehicle. 2. Place a drain pan under the transaxle oil pan. 3. Remove the oil pan bolts from the front and sides only. 4. Loosen the rear oil pan bolts approximately 4 times. Caution: Pry the oil pan carefully in order to prevent damage to the transaxle case or the oil pan sealing surfaces. 5. Lightly tap the oil pan with a rubber mallet or carefully pry in order to allow the oil to drain. 6. Remove the AIR. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Symptom Related Diagnostic Procedures/4T45-E - Automatic Transmission/Transmission Fluid Level and Condition Check). 7. Inspect the fluid color. Page 8270 Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 5359 1 - Fuse Block - Rear Page 8664 Body Control Module (BCM) X2 Page 2853 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Page 6397 Seat Belt Pretensioner - Passenger Page 8542 Disclaimer Page 329 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (LAT) Page 9961 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 6108 Warranty Information (Saab U.S. Models) Disclaimer Page 10067 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 925 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 5195 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 190 Page 3169 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the engine oil pressure switch. Tighten the switch to 22 Nm (16 lb ft). 2. Connect the engine wiring harness electrical connector (2) to the oil pressure switch. 3. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). Page 5709 Inline Harness Connector End Views X600 Body Harness to Right Front Door Harness Page 6378 Outside Rearview Mirror - Driver (DD0) Outside Rearview Mirror - Driver (D49 or DP2) Page 7675 12. Install the compressor hose and liquid line connector. 13. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 14. Leak test the fittings using the J 39400-A. 15. Install the surge tank to the surge tank bracket. Page 2662 Body Control Module (BCM) X3 Page 4669 Installation Procedure 1. Clean the sealing surface of the BPMV with denatured alcohol and a clean shop cloth. 2. Carefully install the EBCM (1) to the BPMV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 4 EBCM bolts (1). Tighten the bolts in a cross pattern to 3 Nm (27 lb in). Note: Ensure the electrical connector is correctly inserted into the EBCM prior to placing the locking lever into position. Failure to make a proper connection may cause communication problems with the module. 4. Connect the electrical connector to the EBCM. 5. If installing a new EBCM, it is necessary to program the EBCM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................... 5.0 quarts (4.7 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 4854 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 6860 1 - Steering Wheel Position Sensor (NVH) Page 5603 Theft Deterrent Module (TDM) Page 2361 Keyless System - Remote Start Transmitter Diagnostic Tip Keyless Start Transmitter: Technical Service Bulletins Keyless System - Remote Start Transmitter Diagnostic Tip INFORMATION Bulletin No.: 09-08-52-004A Date: January 08, 2010 Subject: Diagnostic Tips/Recommendations on GM Accessory 2-Way Remote Start Transmitter When Transmitter Battery is Weak or Dead Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Cobalt, HHR, Impala, Silverado, Tahoe 2009-2010 Chevrolet Malibu, Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2007-2009 Pontiac G5, G6, Solstice, Torrent 2008-2009 Pontiac G8 2007-2010 Saturn AURA, OUTLOOK, SKY, VUE 2007-2010 HUMMER H2 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-52-004 (Section 08 - Body and Accessories). Follow these procedures if a customer comments that their GM Accessory 2-way transmitter stopped communicating with the vehicle. About GM Accessory 2-Way Remote Start The GM Accessory 2-way transmitter has the ability to operate a second vehicle equipped with a 2-way advanced remote start system, but often the 2-way transmitter may only be coded to one vehicle. If the customer presses the left side button twice within one second, the 2-way transmitter will enter second vehicle mode and will not control the original vehicle until a subsequent double press of the left side button places the transmitter back in first vehicle mode. Each vehicle mode of the 2-way transmitter should be thought of as an individual transmitter with its own unique code. Test the Transmitter Battery Note This test should be performed prior to releasing the vehicle or transmitter to the customer. All transmitter batteries should be tested immediately after installation of a 2-way remote start kit or replacement of a transmitter battery using the following procedure. 1. Press the unlock button on the transmitter eight times consecutively. 2. After the eighth press of the unlock button, observe the battery gauge located in the upper right corner of the LCD display. The gauge should read full (three bars inside the battery icon). If after having a new battery installed, the battery goes dead within five months, the transmitter could have high sleep current, causing the battery to go dead. Replace the transmitter. Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. Determine if Transmitter is in Second Vehicle Mode 1. Press and release any of the face buttons on the 2-way transmitter and observe the display on power-up. 2. If the 2-way transmitter is in second vehicle mode, the second vehicle icon will be displayed on the left side of the transmitter display. Is the 2-way transmitter in second vehicle mode? If Yes, the 2-way transmitter is working properly. - Press and release the left side button twice within one second. The 2-way transmitter should exit second vehicle mode. - Press and release the lock button. Press and release the unlock button. Page 10420 Page 4411 1. Install the wheel bearing/hub assembly to the knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 wheel bearing/hub assembly nuts. Tighten the nuts to 63 Nm (47 lb ft). 3. Install the stabilizer link bolt at the knuckle. Refer to Stabilizer Shaft Replacement (See: Steering and Suspension/Suspension/Stabilizer Bar/Service and Repair/Rear Suspension). 4. Connect the electrical connector to the wheel speed sensor. 5. Install the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. Lower the vehicle. Page 4688 Lateral Accelerometer: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor Page 5752 Fuse Block - Underhood X5 (Battery Positive Cable) (without NVH) Fuse Block - Underhood X6 (Battery Positive Cable) Page 2436 Repair/Cooling System Draining and Filling). Heater Core Cover Replacement Heater Core: Service and Repair Heater Core Cover Replacement Heater Core Cover Replacement Removal Procedure 1. Remove the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Housing Assembly HVAC/Service and Repair). 2. Remove the center floor air outlet duct screws. 3. Remove the center floor air outlet duct. 4. Drill out the heater core cover heat stakes. 5. Remove the heater core cover screws. 6. Remove the heater core cover. Page 9977 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the MYLAR tape. If the MYLAR tape is damaged, use 3M product AL-36FR to replace the damaged MYLAR tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Page 4130 Shift Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH2) Page 1463 Fuse Block - Rear X2 Page 4604 Page 3644 Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover Replacement). 13. If a NEW TCM has been installed into the vehicle, the NEW module needs to be reprogrammed. Refer to Service Programming System (SPS) ( See: Testing and Inspection/Programming and Relearning/Service Programming System (SPS)). Note: The Service Fast Learn Adapts procedure must be performed when one of the following repairs have been made to the vehicle. Failure to perform the procedure after one of the following repairs may result in poor transmission performance, as well as transmission DTCs being set: * Transmission internal service/overhaul * Valve body repair or replacement * Control solenoid valve assembly replacement * TCM software/calibration update * Any service in response to a shift quality concern 14. Perform the Service Fast Learn Adapts. Refer to Service Fast Learn Adapts (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning/6T70/6T75 Automatic Transmission). Locations Impact Sensor: Locations SIR Identification Views The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure, refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair). Malibu or Maxx 1 - Right Front Impact Sensor-Located under the hood at the front right side of the vehicle 2 - Front Hood Assist Rod-A gas shock located under the front hood on the passenger side 3 - Passenger Instrument Panel Air Bag-Located at the top right under the instrument panel 4 - Right Roof Rail Air Bag-Located under the headliner, extending from the passenger front windshield pillar to the passenger rear windshield pillar 5 - Right Front Side Impact Sensor (SIS)-Located behind door panel on the passenger front door 6 - Inflatable Restraint Sensing and Diagnostic Module (SDM)-Located underneath the vehicle carpet under the center console 7 - Passenger Seat Side Air Bag-Located on the seat back of passenger seat 8 - Passenger Seat Belt Retractor Pretensioner-Located under the trim near the bottom of the center pillar on the passenger side of vehicle 9 - Inflator Module for Right Roof Rail Air Bag-Located behind the garnish molding on the upper rear pillar 10 - Rear Hood Assist Rod-A gas shock located under the rear truck lid on the passenger side 11 - Rear Hood Assist Rod-A gas shock located under the rear truck lid on the driver side 12 - Inflator Module for Left Roof Rail Air Bag-Located behind garnish molding on the upper rear pillar 13 - Driver Seat Belt Retractor Pretensioner-Located under the trim near the bottom of the center pillar on the driver side of vehicle 14 - Driver Seat Side Air Bag-Located on the seat back of driver seat 15 - Left Front Side Impact Sensor (SIS)-Located behind door panel on the driver front door 16 - Left Roof Rail Air Bag-Located under the headliner, extending from the driver front windshield pillar to the driver rear windshield pillar 17 - Driver Steering Wheel Air Bag-Located on the steering wheel 18 - Front Hood Assist Rod-A gas shock located under the front hood on the driver side 19 - Vehicle Battery-Located at the front left of the engine compartment 20 - Left Front Impact Sensor-Located under the hood at the front left side of the vehicle Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (1 of 2) Page 7525 Note: Make certain that the drive plate does not drag against the pulley when the pulley is rotated. 8. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.3-0.6 mm (0.012-0.024 in) air gap. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Make certain that the new drive plate bolt has colored adhesive on at least 5 threads. 9. Install the clutch drive plate bolt. 10. Tighten the compressor clutch drive plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. Tighten the bolt to 12 Nm (106 lb in). 11. Install the lower air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Lower Baffle and Deflector Replacement). 12. Lower the vehicle. 13. Install the drive belt to the A/C compressor. Refer to Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair) for the 2.4L engine or Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair) for the 3.6L engine. 14. Leak test the fittings using the J 39400-A. Page 1383 Fuse 6 .................................................................................................................................................. ............... Park Lamps, Instrument Panel Dimming Fuse 7 ................................................................. ................................................................................................................................................. Not Used Fuse 8 ........................................................................................................................................ .......................................................................... Not Used Fuse 9 ....................................................... ........................................................................................................................................................... Not Used Fuse 10 ................................................................................................................................ .................................................................... Sunroof Controls Fuse 11 ............................................... .............................................................................................................................................................. ... Not Used Fuse 12 ............................................................................................................................ .................................................................................... Not Used Fuse 13 ........................................... .......................................................................................................................................................... Audio Amplifier Fuse 14 ...................................................................................................................... ....................................................................... Heated Seat Controls Fuse 15 .................................... .............................................................................................................................................................. .............. Not Used Fuse 16 ..................................................................................................................... Remote Keyless Entry (RKE) System, XM Satellite Radio, UGDO Fuse 17 ........................................................................... ........................................................................................................................... Back-up Lamps Fuse 18 ......................................................................................................................................................... ....................................................... Not Used Fuse 19 ........................................................................ ........................................................................................................................................ Not Used Fuse 20 ................................................................................................................................................ ........................................ Auxiliary Power Outlets Fuse 21 ................................................................ ................................................................................................................................................ Not Used Fuse 22 ...................................................................................................................................... .................................................................. Trunk Release Fuse 23 .................................................... ......................................................................................................................................................... Rear Defog Fuse 24 ............................................................................................................................ ........................................................................... Heated Mirrors Fuse 25 ........................................... .............................................................................................................................................................. ..... Fuel Pump RELAYS .............................................................................................................................................. .................................................................... USAGE Relay 26 .............................................................................................................................................. ......................................... Rear Window Defogger Relay 27 .............................................................. ............................................................................................................................................ Park Lamps Relay 28 ................................................................................................................................... ........................................................................... Not Used Relay 29 .................................................. ............................................................................................................................................................ Not Used Relay 30 .............................................................................................................................. ................................................................................ Not Used Relay 31 ............................................. .............................................................................................................................................................. ... Not Used Relay 32 .......................................................................................................................... .................................................................................... Not Used Relay 33 ......................................... ............................................................................................................................................................. Back-up Lamp Relay 34 ...................................................................................................................... ........................................................................................ Not Used Relay 35 ..................................... .............................................................................................................................................................. ........... Not Used Relay 36 .................................................................................................................. .................................................................................... Trunk Release Relay 37 ................................. .............................................................................................................................................................. ............. Fuel Pump Relay 38 .............................................................................................................. ............................................................................. (Diode) Cargo Lamp Page 3721 3 - Torque Converter Assembly 4 - Manual Shaft and Detent Lever Assembly 5 - 2nd Clutch 6 Reverse Clutch 7 - Coast Clutch 8 - Direct Clutch 9 - Reaction Planetary Gear Set 10 - Input Planetary Gear Set 11 - Forward Clutch 12 - Lo Roller Clutch 13 - Parking Lock Actuator Assembly 14 - Differential and Final Drive Assembly 15 - Output Stub Shaft 16 - Output Speed Sensor 17 Lo/Reverse Servo Assembly 18 - Lo/Reverse Band 19 - Oil Feed Tube Assembly 20 - Input Sprag Clutch Assembly 21 - Oil Filter Assembly 22 - 2nd Roller Clutch 23 - Oil Level Control Valve 24 Drive Link Assembly 25 - Driven Sprocket 26 - Output Shaft 27 - Channel Plate Assembly 28 Input Speed Sensor 29 - 4-3 Solenoid 30 - Drive Sprocket 31 - Control Valve Body Assembly 32 Oil Pump Assembly 33 - Auxiliary Pump Disassembled Views Disassembled Views Case and Associated Parts Page 6248 Digital Video Disc (DVD) Display - Driver Seat Headrest X2 (SPO Accessory) (UJ5) Page 6610 Fuse Block - Underhood X3 Interior - Gap At Rear Edge Of Shifter Trim Plate Shifter A/T: All Technical Service Bulletins Interior - Gap At Rear Edge Of Shifter Trim Plate TECHNICAL Bulletin No.: 08-08-49-012B Date: September 21, 2009 Subject: Gap at Rear Edge of Front Floor Console Shifter Trim Plate (Align Mounting Tab) Models: 2008-2010 Chevrolet Malibu Supercede: This bulletin is being revised to add the 2010 model year and to update the Correction information. Please discard Corporate Bulletin Number 08-08-49-012A (Section 08 - Body and Accessories). Condition Some customers may comment on a gap at the rear edge of the floor console shifter trim plate. Cause This condition may be caused by the front floor console accessory trim plate rear clips not fully engaging with the clip slots in the console base. Correction Use the following steps to remove the front floor console accessory trim plate and inspect the trim plate clip towers, clips and the console clip slots for damage. If no damage is found, reinstall the trim plate as described in the procedure. 1. Set the parking brake. 2. Turn the ignition key to the ON position with the engine off (the engine should not be running). 3. Depress the brake pedal and place the shifter into the neutral ("N") position. Note Release the shifter boot from the shifter knob by pulling the boot retainer down in order to gain access to the shift knob front retaining screw. 4. Remove the shift control knob. Refer to Floor Shift Control Knob Replacement in SI. 5. Remove the front floor console trim plate. Refer to Front Floor Console Accessory Trim Plate Replacement in SI. 6. Inspect the underside of the shifter console trim plate for the four white attaching clips and their rib structures. - Inspect all of the shifter plate attachments, including the two small forward tabs. If none of the attachments are damaged and the shifter plate forward tip up bin lid functions properly, DO NOT REPLACE the shifter trim plate. - If any of the four attaching clips are damaged or bent, the console shifter trim plate may need to be replaced. 7. Remove the left and right console side extension panels to provide access to the clip slots in the console base from below. Refer to Front Floor Console Extension Panel Replacement in SI. 8. Position the front floor console accessory trim plate for installation. Refer to Front Floor Console Accessory Trim Plate Replacement in SI. Page 4371 5. Remove the housing (1) from the tripot joint spider and the halfshaft bar (2). 6. Spread the spacer ring (1) using J 8059 (or equivalent). Page 7184 3. Reconnect the wheel speed senor electrical connector, if needed. 4. Install the wheel speed sensor electrical connector on the retaining bracket, if needed. 5. Install the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 6. Install the wheel drive shaft retaining nut and washer. Refer to Wheel Drive Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement). 7. Remove the support and lower the vehicle. Page 10407 Page 7062 12. If the steering gear has a female rack (1) and a male inner tie rod (3), remove the old LOCTITE(R) from the threads (2) on the inner tie rod and from the threads on the rack. If the steering gear has a male rack (5) and a female inner tie rod (4), LOCTITE(R) will not be present. Assembly Procedure Note: The threads must be clean prior to LOCTITE(R) application. Inspect the LOCTITE(R), or equivalent, container for the expiration date. Use only enough LOCTITE(R) to evenly coat the threads. If the steering gear has a male rack (5) and a female inner tie rod (2), do not apply LOCTITE(R). 1. If the steering gear has a female rack (1) and a male inner tie rod (3), apply LOCTITE(R) 262, or equivalent, to the threads (2) on the left inner tie rod. 2. Install the left inner tie rod to the rack (3). 3. Place a pipe wrench on the rack next to the left inner tie rod housing (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Place a torque wrench and the J-34028 - wrench on the flats of the left inner tie rod housing. Tighten the inner tie rod to 100 Nm (74 lb ft). Page 1474 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 9507 Seat Fan: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 4399 13. Push the CV joint (2) onto the halfshaft bar (1) until the retaining ring is seated in the groove on the halfshaft bar. Note: The outboard seal (1) must not be dimpled, stretched or out of shape in any way. If the outboard seal (1) is not shaped correctly, equalize the pressure in the outboard seal (1) and shape the seal properly by hand. 14. Slide large diameter of the outboard seal (1) with the large seal retaining clamp (2) in place over the outside of the CV joint outer race (3) and locate the seal lip in the groove on the CV joint outer race. Page 9976 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. Page 2468 Note: Rotate the pigtail 90 degrees from vertical before securing the fastener. 1. Install the knock sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the knock sensor bolt and tighten to 25 Nm (18 lb ft). 3. Install the knock sensor electrical connector pigtail (6) clip to the oil level indicator tube bracket. 4. Connect the engine wiring harness electrical connector (1) to the knock sensor pigtail electrical connector (6). 5. Lower the vehicle. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Page 2839 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Locations Parking Brake Release Switch: Locations Instrument Panel/Center Console Component Views Lower Left Side of the Instrument Panel Components (2 of 2) 1 - Park Brake Release 2 - Park Brake Switch 3 - Dash Panel 4 - Park Brake Lever Page 6425 Sunload Sensor (C68) Sunroof Control Module (CF5) Page 8034 Seat Belt: Service and Repair Seat Belt Latch Stop Installation Service and Repair High Pressure Safety Valve HVAC: Service and Repair Compressor Pressure Relief Valve Replacement Page 10183 Page 7987 Your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle not only meets, but exceeds government standards for side impact protection. GM recently introduced into production, changes that add to that protection. At no charge, your dealer will make similar changes to your vehicle, which was built before the production change. What We Will Do: To enhance the side impact protection, your GM dealer will update the wiring harness for both front seat side impact airbags. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 10085 Page 7947 Your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle not only meets, but exceeds government standards for side impact protection. GM recently introduced into production, changes that add to that protection. At no charge, your dealer will make similar changes to your vehicle, which was built before the production change. What We Will Do: To enhance the side impact protection, your GM dealer will update the wiring harness for both front seat side impact airbags. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 10085 Page 9188 within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) Page 8033 Disclaimer Page 8209 Page 10612 Power Window Switch: Diagrams Component Connector End Views Window Switch - Driver X1 Window Switch - Driver X2 Page 238 Fuse Block - Underhood X5 (Battery Positive Cable) (without NVH) Fuse Block - Underhood X6 (Battery Positive Cable) Page 5789 Fuse Block - Rear X1 Service and Repair Oil Spray Jet: Service and Repair Piston Oil Nozzle Replacement Removal Procedure 1. Remove the engine oil pan. Refer to Oil Pan Replacement (See: Oil Pan/Service and Repair). 2. Rotate the crankshaft so that cylinders 1 and 4 are at top dead center (TDC). 3. Remove the piston oil nozzles from cylinders 1 and 4 using a 3/8 inch wobble extension drive with a 6 mm hex drive bit. Remove the piston oil nozzles. (Crankshaft removed for illustrative purposes.) 4. Rotate the crankshaft so that cylinders 2 and 3 are at TDC. Remove the piston oil nozzles. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Page 6935 Steering Control Module: Diagrams Component Connector End Views Electric Power Steering (EPS) Module X1 (without NVH) Electric Power Steering (EPS) Module X2 (without NVH) Page 10044 Cigarette Lighter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 8689 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia Replacement Front Bumper Fascia Replacement Page 5308 FUSES ................................................................................................................................................. ..................................................................... USAGE POWER MIRRORS ............................................................................................................................. ...................................................... Power Mirrors EPS ....................................................................... .................................................................................................................... Electronic Power Steering RUN/CRANK ......................................................................................................................... Cruise Control Switch, Passenger Airbag Status Indicator HVAC BLOWER HIGH ............................................................................................ Heating Ventilation Air Conditioning Blower - High Speed Relay CLUSTER/THEFT .............................................................................................................................. Instrument Panel Cluster, Theft Deterrent System ONSTAR .......................................................................................... ...................................................................................................................... OnStar NOT INSTALLED ......................................................................................................................................... .................................................... Not Used AIRBAG (IGN) ................................................................ ...................................................................................................................... Airbag (Ignition) HVAC CTRL (BATT) ................................................................... Heating Ventilation Air Conditioning Control Diagnostic Link Connector (Battery) PEDAL .......................................................................... ...................................................................................................................................... Not Used WIPER SW .......................................................................................................................................... ........................ Windshield Wiper/Washer Switch IGN SENSOR ....................................................... ..................................................................................................................................... Ignition Switch STRG WHL ILLUM ............................................................................................................................................................. Steering Wheel Illumination NOT INSTALLED .................................................................................... ......................................................................................................... Not Used RADIO ....................... .............................................................................................................................................................. .................... Audio System INTERIOR LIGHTS ................................................................................. ................................................................................................. Interior Lamps NOT INSTALLED ...... .............................................................................................................................................................. ......................... Not Used POWER WINDOWS .................................................................................. ............................................................................................. Power Windows HVAC CTRL (IGN) .................................................................................................................. Heating Ventilation Air Conditioning Control (Ignition) HVAC BLOWER ........................................................................................................................... Heating Ventilation Air Conditioning Blower Switch DOOR LOCK ..................................................................................... ............................................................................................................. Door Locks ROOF/HEAT SEAT ................................................................................................................................................... ...................... Sunroof, Heated Seat NOT INSTALLED ...................................................................... ....................................................................................................................... Not Used NOT INSTALLED ......................................................................................................................................... .................................................... Not Used AIRBAG (BATT) ............................................................. ....................................................................................................................... Airbag (Battery) SPARE FUSE HOLDER ...................................................................................................................... ................................................ Spare Fuse Holder SPARE FUSE HOLDER ...................................... ................................................................................................................................ Spare Fuse Holder SPARE FUSE HOLDER .......................................................................................................... ............................................................ Spare Fuse Holder SPARE FUSE HOLDER .......................... ............................................................................................................................................ Spare Fuse Holder Page 148 Page 3051 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 5163 Page 9602 Page 805 1. Lubricate the CKP sensor O-ring seal with clean engine oil. 2. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CKP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 5. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 6. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Page 5397 Camshaft Position (CMP) Sensor - Bank 1 Exhaust (LY7) Page 4277 Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 4. Remove the transaxle range switch lever nut and lever. 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. Page 7543 18. Install the right radiator air deflector. 19. Install the right radiator air deflector retainers. 20. Install the right front fender liner. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 21. Install the lower radiator air deflector. 22. Install the lower radiator air deflector retainers. 23. Lower the vehicle. 24. Remove the rope attached to the radiator and upper tie bar. Page 2036 ‹› If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump Electrical Circuit Diagnosis). 2. Ignition OFF, all accessories OFF, install a CH 48027 - Pressure Gauge. Refer to Fuel Pressure Gauge Installation and Removal (See: Fuel Pressure Gauge Installation and Removal). 3. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and does not decrease more than 34 kPa (5 psi) in 1 minute. Circuit/System Testing Note: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel pressure gauge while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Install the J 37287 - Shut-off Adapter or the J 37287-FF Adapter between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 - Shut-off Adapter or the J 37287-FF - Adapter. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the CH 48027 - Gauge. 5. Command the fuel pump relay ON and then OFF with a scan tool. 6. Close the valve on the J 37287 - Shut-off Adapter or the J 37287-FF Adapter. 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injectors. ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with the CH 48027 - Gauge. The fuel pressure should not drop off during acceleration, cruise, or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Line Replacement - Chassis (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair) * Fuel Injector Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair) * Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) Page 2427 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. (Intake CMP shown, exhaust CMP similar). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect engine wiring harness electrical connector (5) to the exhaust CMP sensor (4). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 3540 Ignition Coil: Testing and Inspection Electronic Ignition System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The ignition system uses individual ignition coil/module assemblies for each cylinder. The engine control module (ECM) controls the individual coils by transmitting timing pulses on the ignition control (IC) circuit of each ignition coil/module to enable a spark event. Each ignition coil/module has the following circuits: * Ignition voltage * Ground * IC * Low reference Diagnostic Aids * Depending on location in the spliced ignition voltage circuit, a slight resistance can cause a misfire or a crank/no start concern. A voltage drop test on the circuit will pinpoint this condition. * A slight to moderate resistance on any IC circuit can cause a misfire before DTC P0351-P0354 sets. * Extended engine cranking time, may foul the spark plugs with excessive fuel. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools J 26792 HEI Spark Tester Circuit/System Verification 1. Verify that the engine is in good mechanical condition before continuing with this diagnostic. 2. Verify the following conditions: * The ignition coil/modules are correctly connected * The proper firing order * The proper spark plug type * The proper spark plug gap and torque Page 2804 Page 5247 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Locations Traction Control Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 8228 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Page 9489 Page 862 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 2 Heated Oxygen Sensor Replacement - Sensor 2 Page 1188 5. Reposition the idler pulley (2) to release tension off the drive belt. 6. Remove the drive belt from under the middle idler pulley. 7. Remove the drive belt from the vehicle. Installation Procedure 1. Install and position the drive belt around all of the pulleys except for the middle idler pulley. 2. Install the drive belt under the middle idler pulley. 3. Reposition the idler pulley (2) to install the drive belt. 4. Install the drive belt under the middle idler pulley. 5. Ensure the drive belt tensioner idler pulley is fully seated against the drive belt. 6. Loosen the forcing bolt on the EN-48932 - compressor (1) and remove from the drive belt tensioner spring. 7. Ensure that the drive belt tensioner idler is fully seated against the drive belt. Page 4946 1. Maneuver the vacuum brake booster into position in the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the (2) brake pedal assembly nuts and tighten to 15 Nm (11 lb ft). 3. Install the wave washers (2) and connect the brake pedal pushrod (3) to the pedal pivot pin (4). Do not apply excessive side pressure on the pushrod. 4. Install the brake pedal pushrod retainer clip (1). 5. Connect the brake pedal position sensor electrical connector. 6. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). Page 1259 9. Remove the suction hose from the dash clip. 10. Remove the line clip from the dash. 11. Remove the refrigerant pressure sensor wire harness connector. 12. Remove the liquid line bracket bolt. Electrical - Various Electrical Concerns/False Messages Door Switch: All Technical Service Bulletins Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Page 2750 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 8463 Page 2891 within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) Page 9343 Sunroof / Moonroof Track: Removal and Replacement Sunroof Housing Drain Gutter Replacement Removal Procedure 1. Apply a double layer of masking tape to the roof panel along the rear edge of the sunroof opening. 2. Cycle the sunroof window to the vent position, then to 25 mm (1 in) rearward. 3. Remove the sunroof module assembly. Refer Sunroof Frame Replacement (See: Sunroof / Moonroof Frame/Service and Repair). 4. From the underside of the sunroof window track assembly, remove the 3 screws that secure the water gutter to the forward cross-member of the track assembly. Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Page 8264 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors Tyco/AMP Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 3433 12. Connect the engine wiring harness electrical connector (3) to the fuel injector wiring harness electrical connector (4). 13. Connect the fuel feed line quick connect fitting (3) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 14. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 16. Inspect for fuel leaks using the following procedure: 1. Turn ON the ignition, with the engine OFF for 2 seconds. 2. Turn OFF the ignition for 10 seconds. 3. Turn ON the ignition. 4. Inspect for fuel leaks. Page 6534 Page 1253 16. Remove the liquid line and compressor hose from the condenser. 17. Remove the liquid line from the rail clip. 18. Lower the vehicle. Page 1907 1. Install the NEW oil filter to the cap. 2. Install the oil filter cap and filter. Caution: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. Note: DO NOT use an open end wrench on the hex on top of the oil filter cap. 3. use an oil filter wrench on the outside diameter of the oil filter cap. Tighten the oil filter cap until fully seated. DO NOT exceed 25 Nm (18 lb ft). 4. Fill the engine with oil. Refer to Fluid and Lubricant Recommendations (See: Maintenance). Page 5040 Page 10279 Center Mounted Brake Lamp: Service and Repair High Mount Stop Lamp Replacement Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Switch Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the oil pressure switch. 3. Remove the engine oil pressure switch. Installation Procedure Page 7673 13. Remove the suction hose. Note: Cap all A/C components immediately to prevent system contamination. 14. Remove and discard the sealing washers. Installation Procedure 1. Uncap A/C components. 2. Install new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 3. Install the suction hose. Locations Knock Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Lower Front and Rear of the Engine Components (LY7) Page 4895 4. Install the BPMV and bracket assembly. 5. Install the 3 BPMV bracket nuts (1) and tighten to 10 Nm (89 lb in). 6. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. Connect the master cylinder secondary brake pipe fitting (1) and tighten the fitting to 32 Nm (24 lb ft). Page 2136 3. Install the heater inlet hose to the heater core. 4. Reposition the heater inlet hose clamp at the heater core using the J 38185. 5. Install the surge tank to the surge tank bracket. 6. Fill the coolant. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). Page 5469 Fuel Injector 2 (LY7) Fuel Injector 2 (LZ4 or LZE) Page 10137 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Service and Repair Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor Replacement Removal Procedure Warning Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. 1. Position the vehicle on a hoist and raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector. 3. Remove the VSS electrical harness retainer from the VSS stud. 4. Remove the VSS stud. 5. Remove the output VSS from the transmission case. Note: Inspect the O-ring for damage and replace if necessary. 6. Remove the O-ring from the VSS. Installation Procedure Page 9497 Page 10339 Hazard Warning Switch: Diagrams Component Connector End Views Hazard Warning Switch Page 6359 Inflatable Restraint Side Impact Sensor (SIS) - Right Wheels/Tires - Use of Nitrogen Gas in Tires Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Page 5233 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 2658 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Locations Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 9656 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 139 Page 350 Engine Control Module: Service and Repair Engine Control Module Replacement Removal Procedure Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Disconnect the body wiring harness electrical connector (1) from the engine control module (ECM). Page 7453 2. Install the right hand side window defogger duct screws and tighten to 2.5 Nm (22 lb in). 3. Install the I/P assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Rear Floor Air Duct Replacement Rear Floor Air Duct Replacement Removal Procedure 1. Remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 2. Remove the Instrument panel lower bracket. Refer to Instrument Panel Lower Bracket Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Bracket Replacement). 3. Remove the center floor air duct screws. 4. Remove the center floor air duct. Installation Procedure Page 6020 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Page 5852 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. 2008 Model Year Buick Enclave, GMC Acadia and Saturn OUTLOOK Vehicles Only Note The seat mounted side impact airbag connection to the body harness is located at the forward edge of the seat, below the plastic trim. The connectors are yellow. The body harness wires are exposed - running forward in the vehicle, down through the carpet cutout in the floor. Page 8893 Body Emblem: Service and Repair Radiator Grille Emblem/Nameplate Replacement Radiator Grille Emblem/Nameplate Replacement Page 6148 Body Control Module (BCM) X2 Page 1420 Fuse Block - Rear X2 Page 6141 Fuse 6 .................................................................................................................................................. ............... Park Lamps, Instrument Panel Dimming Fuse 7 ................................................................. ................................................................................................................................................. Not Used Fuse 8 ........................................................................................................................................ .......................................................................... Not Used Fuse 9 ....................................................... ........................................................................................................................................................... Not Used Fuse 10 ................................................................................................................................ .................................................................... Sunroof Controls Fuse 11 ............................................... .............................................................................................................................................................. ... Not Used Fuse 12 ............................................................................................................................ .................................................................................... Not Used Fuse 13 ........................................... .......................................................................................................................................................... Audio Amplifier Fuse 14 ...................................................................................................................... ....................................................................... Heated Seat Controls Fuse 15 .................................... .............................................................................................................................................................. .............. Not Used Fuse 16 ..................................................................................................................... Remote Keyless Entry (RKE) System, XM Satellite Radio, UGDO Fuse 17 ........................................................................... ........................................................................................................................... Back-up Lamps Fuse 18 ......................................................................................................................................................... ....................................................... Not Used Fuse 19 ........................................................................ ........................................................................................................................................ Not Used Fuse 20 ................................................................................................................................................ ........................................ Auxiliary Power Outlets Fuse 21 ................................................................ ................................................................................................................................................ Not Used Fuse 22 ...................................................................................................................................... .................................................................. Trunk Release Fuse 23 .................................................... ......................................................................................................................................................... Rear Defog Fuse 24 ............................................................................................................................ ........................................................................... Heated Mirrors Fuse 25 ........................................... .............................................................................................................................................................. ..... Fuel Pump RELAYS .............................................................................................................................................. .................................................................... USAGE Relay 26 .............................................................................................................................................. ......................................... Rear Window Defogger Relay 27 .............................................................. ............................................................................................................................................ Park Lamps Relay 28 ................................................................................................................................... ........................................................................... Not Used Relay 29 .................................................. ............................................................................................................................................................ Not Used Relay 30 .............................................................................................................................. ................................................................................ Not Used Relay 31 ............................................. .............................................................................................................................................................. ... Not Used Relay 32 .......................................................................................................................... .................................................................................... Not Used Relay 33 ......................................... ............................................................................................................................................................. Back-up Lamp Relay 34 ...................................................................................................................... ........................................................................................ Not Used Relay 35 ..................................... .............................................................................................................................................................. ........... Not Used Relay 36 .................................................................................................................. .................................................................................... Trunk Release Relay 37 ................................. .............................................................................................................................................................. ............. Fuel Pump Relay 38 .............................................................................................................. ............................................................................. (Diode) Cargo Lamp Rear Side Door Trim Panel Replacement Rear Door Panel: Service and Repair Rear Side Door Trim Panel Replacement Rear Side Door Trim Panel Replacement Page 5777 Fuse Block - Underhood X1 Page 5843 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Front Floor Console Accessory Trim Plate Replacement Console: Service and Repair Front Floor Console Accessory Trim Plate Replacement Front Floor Console Accessory Trim Plate Replacement Page 10728 3. Apply bonded-glass primer and let dry per auto-adhesive instructions by the manufacturer's. 4. Apply the auto-adhesive primer-application (2) around the perimeter of the rear window (1) and let dry per auto-adhesive instructions by the manufacturer's. 5. Cut the applicator nozzle to provided a V cut to apply the auto-adhesive. Note: If the locating pins were cut off it will be necessary to tape the window in place until the auto-adhesive cures per auto-adhesive instructions by the manufacturer's. 6. With an assistant, use the glass handling cups, align the windshield locating pins to the slots located in each corner of the pinch-weld flange. Lower the windshield to touch the auto-adhesive. 7. Remove the glass handling cups. Page 228 Fuse Block - Underhood Top View (LY7) Page 1771 11. Install the upper timing chain guide and bolts and tighten to 10 Nm (89 lb in). 12. Install the camshaft cover. Refer to Camshaft Cover Replacement (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 13. Install the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). Page 6444 Vehicle Communication Interface Module (VCIM) X3 (UE1) Page 6340 Ignition Coil 1 (LY7) Service and Repair Front Bumper Shock Absorber: Service and Repair Front Bumper Fascia Energy Absorber Replacement Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor Replacement - Intake Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (7) from the intake camshaft position (CMP) sensor (6). 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. Installation Procedure Locations Data Link Connector: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 6390 Rear Window Defogger Grid X2 Recirculation Actuator (C60) Page 10118 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Page 7075 17. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 18. Lower the vehicle. 19. Realign the rear suspension. Refer to Wheel Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement). Diagrams Entertainment System Control Module: Diagrams Electrical Center Identification Views Fuse Holder - Digital Video Disc (DVD) Control Module (UJ5) Page 6028 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Page 990 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become UN-centered and cause possible damage to the SIR coil. If you think the SIR coil has became UN-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Page 7223 Frequently Asked Questions Disclaimer Page 792 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Locations Seat Heater Control Module: Locations Passenger Compartment/Roof Component Views Seat Components - Driver 1 - Seat Back Cover - Driver 2 - Heated Seat Element - Driver Back (KA1) 3 - Seat Back Cushion Pad - Driver 4 - Seat Recline Motor - Driver (1LZ) 5 - Seat Horizontal Motor - Driver (AG1 or 1LZ) 6 - Seat Rear Vertical Motor - Driver (AG1 or 1LZ) 7 - Heated Seat Control Module - Driver (KA1) 8 Seat Front Vertical Motor - Driver (AG1 or 1LZ) 9 - Seat Recline Switch - Driver (1LZ) 10 - Seat Adjuster Switch - Driver 11 - Seat Belt Switch - Driver 12 - Seat Cushion - Driver 13 - Heated Seat Element - Driver Cushion (KA1) 14 - Seat Cover - Driver Passenger Compartment/Roof Component Views Page 320 For vehicles repaired under warranty use the table above. Disclaimer Page 2227 7. Remove the upper exhaust manifold bolts. 8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 9. Remove the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Left Side). 10. Remove the lower exhaust manifold bolts. 11. Remove the exhaust manifold. 12. Remove and discard the exhaust manifold gasket. Installation Procedure 1. Install a NEW exhaust manifold gasket onto the cylinder head studs. 2. Install the exhaust manifold. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the exhaust manifold bolts. Page 6510 X181 Inline Harness Connector End Views X181 Right Repeater Lamp Harness to Forward Lamp Harness X206 Inline Harness Connector End Views X206 I/P Harness to Body Harness Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Special Tools J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove and support the brake caliper and bracket as an assembly, and remove the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement ). 4. Rotate the bearing hub to a position where the least amount of interference between the stud and the steering knuckle exists. 5. Using the J 43631, release the wheel stud from the bearing hub and discard the stud. Installation Procedure Page 10490 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 6435 Traction Control Switch (TCS) Transmission Control Module (TCM) (ME7) Page 3069 Engine Control Module (ECM) X3 (LAT) Page 6709 For vehicles repaired under warranty, use the table. Disclaimer Page 481 Page 7115 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Page 7235 1. Clean the area around the mounting point for the tire pressure sensor. 2. Install the washer (2) and the seal (3) on the tire pressure sensor (1). 3. Install the tire pressure sensor (1) on the wheel. 4. Start the nut (4) by hand. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: When installing the tire pressure sensor and the nut, position the tire pressure sensor so that it is parallel to the inside wheel surface while torquing. 5. Install the nut (2) on the tire pressure sensor (1). Tighten the nut (2) to 7 Nm (62 lb in). 6. Install the tire on the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 7. Install the tire/wheel assembly on the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 8. Lower the vehicle. Page 458 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 5208 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Delphi Connectors Delphi Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Specifications Wheel Fastener: Specifications Wheel nuts ........................................................................................................................................... ..................................................... 140 Nm (100 lb ft) Page 141 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement Removal Procedure Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 1. Turn the ignition switch to the OFF position. 2. Clean the electronic brake control module (EBCM) to brake pressure modulator valve (BPMV) area of any accumulated dirt and foreign material. 3. Disconnect the electrical connector from the EBCM. 4. Remove the 4 EBCM bolts (1). 5. Separate the EBCM (1) from the BPMV by carefully pulling the components apart. Page 8166 Antilock Brake System Automated Bleed Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Antilock Brake System Automated Bleed Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Note: * Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Hydraulic Brake System Bleeding). * The automated bleed procedure must be performed when a new brake pressure modulator valve (BPMV) is installed, because the secondary circuits of the new BPMV are not prefilled with brake fluid. * The automated bleed procedure is recommended when one of the following conditions exist: * Base brake system bleeding does not achieve the desired pedal height or feel * Extreme loss of brake fluid has occurred * Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out away from the brake modulator assembly, which is then forced out at the brake corners by the pressure bleeder. Automated Bleed Procedure Caution: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Repair or replace components as needed. 4. Lower the vehicle. 5. Prepare the brake bleeding equipment and the vehicle for a pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Hydraulic Brake System Bleeding). 6. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). 7. Install a scan tool. 8. Turn the ignition ON, with the engine OFF. 9. With the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Special Functions 6. Select Automated Bleed 10. With an assistant ready, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: * Apply the brake pedal when instructed, using moderate effort. * Ensure the pedal remains applied until instructed to release by the scan tool. * Do not exceed the time period allowed by the scan tool for having the bleeder valves open. * The bleed sequence for each corner is as follows: - Left front - Right front - Right rear Page 1508 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Body - Marks/Stains on Windshield When Wet Windshield: All Technical Service Bulletins Body - Marks/Stains on Windshield When Wet TECHNICAL Bulletin No.: 09-08-48-002A Date: March 19, 2009 Subject: Marks/Stains on Windshield When Wet (Clean Windshield) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories). Condition Some owners may comment that marks/stains appear on the windshield when the windshield is wet. Cause This condition may be caused by contact between the windshield and the vacuum hoses or other tools used in the assembly process. This contact may leave a residue that creates a water repellent surface on the glass which, in wet conditions, appear as marks/stains on the surface. Correction Important DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION. To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's directions for product use. Use only hand tools. DO NOT USE POWER TOOLS. Parts Information Eastwood Glass Polishing Compound 1-800-343-9353 (for overseas inquiries: +1-610-705-2200) http://www.eastwoodco.com/ *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5964 Page 8669 Page 8769 Disclaimer Page 2242 3. Remove the exhaust manifold/catalytic converter to exhaust manifold pipe nuts. 4. Remove the first muffler hanger insulator. 5. Gently pull back and separate the muffler from the exhaust manifold pipe studs. 6. Remove the exhaust manifold pipe. Installation Procedure 1. Install the exhaust manifold pipe to the exhaust manifold/catalytic converter. 2. Gently pull back and install the exhaust manifold pipe studs to the muffler. 3. Install the first muffler hanger insulator. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the exhaust manifold/catalytic converter to exhaust manifold pipe nuts and tighten to 30 Nm (20 lb ft). 5. Install the exhaust manifold pipe to muffler nuts and tighten to 25 Nm (18 lb ft). 6. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Sensor 2 (See: Powertrain Management/Computers and Control Locations Trunk / Liftgate Switch: Locations Door Component Views Driver Door Components 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Page 4397 Note: Place a towel in the vise before inserting the halfshaft. 1. Mount the halfshaft into a vise. 2. Install the new small eared clamp (2) on the neck of the outboard seal (1). Do not crimp. 3. Slide the outboard seal (1) onto the halfshaft bar and position the neck of the outboard seal (1) in the seal groove on the halfshaft bar. The largest groove below the sight groove on the halfshaft bar is the seal groove (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Crimp the eared clamp (1) using the J 35910, a breaker bar, and a torque wrench. Tighten the eared clamp to 136 Nm (100 lb ft). 5. Check the gap dimension, continue tightening until the gap dimension is reached. Page 1459 Fuse Block - Rear Bottom View Page 4451 Control Module: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Page 5753 Page 1716 1. Install a NEW stud into the bearing/hub assembly. Add enough washers (3) in order to draw the stud into the hub. 2. Install and tighten a wheel nut (1) until the head of the wheel stud is fully seated against the back of the bearing/hub flange. 3. Remove the wheel nut (1) and the washers (3). 4. Install the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. Campaign - Service Air Bag Message, Replace Connectors Technical Service Bulletin # 11034 Date: 110314 Campaign - Service Air Bag Message, Replace Connectors CUSTOMER SATISFACTION Bulletin No.: 11034 Date: March 14, 2011 Subject: 11034 - Service Air Bag Message - Replace Connectors Models: 2010 Chevrolet Malibu 2010 Pontiac G6 Some, but not all, of the vehicles involved in this Program were also involved in Customer Satisfaction Program (CSP) 10085. These vehicles are to be inspected to determine if the repair for CSP 10085 included the replacement of the two connectors. If the connectors were replaced, no further action is required on these vehicles. If they were not replaced, dealers are to install the new connectors. Condition Certain 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may have a condition in which wear could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact airbag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG system warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG system DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Some of these vehicles were previously repaired under Customer Satisfaction Program 10085. These vehicles had the wire harness secured, and in some cases, rerouted. They did not require the installation of the two connectors. However, there have been reports of the SERVICE AIR BAG message illuminating in the Driver Information Center after the repair, due to movement of the connector between the body main wiring harness and the front driver and passenger side impact air bag. With this Customer Satisfaction Program, dealers will install the two new connectors. Correction Dealers are to inspect and, if necessary, replace the front seat-mounted side impact air bag connectors. Vehicles Involved Involved are certain 2010 model year Chevrolet Malibu and Pontiac G6 vehicles. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty Management system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Page 5479 Generator X1 (LY7) Generator X1 (LZ4 or LZE) Page 4648 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt (2) M6 x 23. 4. Remove the input speed sensor (3). 5. Remove the 3 input speed sensor seals (1). Installation Procedure Page 2854 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 6438 Transmission Control Module (TCM) (MN5 with LZ4 or LZE) Page 8995 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Page 5966 Driver or Passenger Seat Belt Buckle Replacement Seat Belt Buckle: Service and Repair Driver or Passenger Seat Belt Buckle Replacement Driver or Passenger Seat Belt Buckle Replacement Service and Repair Thermostat Housing: Service and Repair Engine Coolant Thermostat Housing Replacement Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). Note: A drain has been provided at the bottom of the water pump for engine block coolant drainage. 2. Drain the coolant from the engine block at the water pump drain. After the coolant has drained, tighten the drain bolt. 3. Lower the vehicle. 4. Remove the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair). 5. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor. 6. Remove the heated oxygen sensor (HO2S) electrical connector rosebud clip from the thermostat housing. Page 9101 Page 7078 7. Remove the trailing arm and the bracket (2) from the frame (3) and the knuckle (1). 8. Remove the bolt and nut from the trailing arm bracket to the trailing arm. Installation Procedure Page 1348 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Hydraulic Brake System Bleeding Special Tools * J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent * J-35589-A - Master Cylinder Bleeder Adapter For equivalent regional tools, refer to Special Tools (See: Brakes and Traction Control/Hydraulic System/Tools and Equipment). Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (See: ) If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Master Cylinder Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent. Add GM approved brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent, to the J-35589-A - Master Cylinder Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent,, air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left front hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a Page 1689 Wheels: Description and Operation Replacement Wheels Description Replace the wheel if any of the following conditions exist: * The wheel exhibits excessive runout. * The wheel is bent. * The wheel is cracked. * The wheel is severely corroded. Note: Air leaks caused by porosity on aluminum wheels are repairable. * The wheel leaks air. Warning If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Caution: The use of non-GM original equipment wheels may cause: * Damage to the wheel bearing, the wheel fasteners and the wheel * Tire damage caused by the modified clearance to the adjacent vehicle components * Adverse vehicle steering stability caused by the modified scrub radius * Damage to the vehicle caused by the modified ground clearance * Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: * The wheel has elongated bolt holes. * The wheel/nuts, or bolts if applicable, loosen repeatedly. Aluminum wheel identification is cast into the inboard side of the wheel. Page 302 - Select Fuel Composition Reset (F1). - The first parameter is "Fuel Alcohol Content" displayed as a percentage. If the Fuel Alcohol Content percentage is above 25%, this is the probable cause of DTC P0172. - From this screen the "Fuel Alcohol Content" can be reset to zero by pressing the lower right Tech 2(R) button. It will then display 0% when it's reset. Finally, reprogram the PCM with the latest calibration. This will correct for the PCM alcohol calculations. Note The PCM must be reset from this screen. It does not reset to zero when the PCM is reprogrammed. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4610 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (ME7 or MN5) Page 1161 Spark Plug: Testing and Inspection Spark Plug Inspection Spark Plug Usage * Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling - colder plug - Pre-ignition causing spark plug and/or engine damage - hotter plug Spark Plug Inspection * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. * Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Page 1599 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. For combination repair/plug units skip this step. Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Page 1644 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 9234 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement Page 8087 Page 1317 Fluid - A/T: Service and Repair Transmission Fluid Replacement Page 9877 Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 1422 Page 7257 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Page 6362 Inflatable Restraint Steering Wheel Module Coil X2 Page 6418 Starter Generator Control Module (SGCM) X2 (LAT) Page 10384 Service and Repair Sunroof / Moonroof Weatherstrip: Service and Repair Sunroof Window Seal Replacement Removal Procedure 1. Remove the sunroof window panel. Refer to Sunroof Window Replacement (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair). 2. Remove the seal from the window panel frame by pulling the seal away at one point and continuing around the perimeter of the frame. 3. Wipe the perimeter of the frame area with a clean dampened cloth. Allow to air dry. Installation Procedure 1. Using a clean dampened cloth wipe the seal with a small amount of the same window cleaner in order to ease installation. 2. Position the sunroof window panel seal onto the window frame, locating the starting end of the seal at the relief notch in the center of the passenger side of the frame. Important: Ensure that the seal is properly seated around the entire perimeter of the window frame. 3. Firmly press the window seal into place. A small rubber hammer will help in the installation. 4. Install the sunroof window panel. Refer to Sunroof Window Replacement (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Service and Repair). 5. Adjust the window panel height. Refer to Sunroof Window Height and Opening Fit Adjustment (See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Panel/Adjustments). 6. Inspect sunroof for proper operation. Page 6538 Inline Harness Connector End Views X600 Body Harness to Right Front Door Harness Page 6485 Battery Disconnect Switch (HP7) Blower Motor Page 6303 Fuel Injector 5 (LZ4 or LZE) Page 6518 X304 Inline Harness Connector End Views X304 Body Harness to Console Harness Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 4512 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt (2) M6 x 23. 4. Remove the input speed sensor (3). 5. Remove the 3 input speed sensor seals (1). Installation Procedure Page 7649 3. Install the heater inlet hose to the heater core. 4. Reposition the heater inlet hose clamp at the heater core using the J 38185. 5. Install the surge tank to the surge tank bracket. 6. Fill the coolant. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). Page 5311 FUSES ................................................................................................................................................. ..................................................................... USAGE Fuse 1 .................................................................................................................................................. ......................................... Passenger Seat Controls Fuse 2 ............................................................... ................................................................................................................................. Driver Seat Controls Fuse 3 ................................................................................................................................... ............................................................................... Not Used Fuse 4 .................................................. .............................................................................................................................................................. .. Not Used Fuse 5 ............................................................................................................................... ......................................... Emission 2, Canister Vent Solenoid Page 1852 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: * The drive belt * The drive belt tensioner * The drive belt idler pulley * The crankshaft balancer pulley * The accessory drive component mounting brackets * The accessory drive components - The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend backward and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubber (chloroprene or EPDM) and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Page 541 Power Mirror Switch: Diagrams Component Connector End Views Outside Rearview Mirror Switch Locations Horn Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 9965 GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The Service and Repair Front Door Interior Handle: Service and Repair Front Side Door Inside Handle Replacement Removal Procedure 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair/Front Side Door Trim Panel Replacement). 2. Remove the front door inside handle to front door by cutting the 2 integral ribs (1) which retain the bezel (3) to the door trim panel. 3. Remove light tube (2) from top of bezel (3). 4. Disconnect electrical connector. Installation Procedure 1. Install new door inside handle bezel (3) to door trim panel by snapping into place till secure. 2. Install light tube (2) to top of bezel. Page 5354 Page 2857 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 10111 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Interior - Cleaning Interior Surfaces of Vehicle Carpet: Technical Service Bulletins Interior - Cleaning Interior Surfaces of Vehicle INFORMATION Bulletin No.: 06-00-89-029F Date: April 27, 2010 Subject: Interior Cleaning - Instrument Panel (IP), Hard or Plastic Surfaces, Seats, Carpet, Leather, Vinyl, Fabric Cleaner, Stain Remover, Restorer - Product Availability Models: 2006-2011 GM Passenger Cars and Trucks including Saturn (EXCLUDES Cadillac DTS Platinum and Escalade Platinum with RPO R9N - Tehama Leather) 2006-2010 HUMMER H2, H3 2006-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-00-89-029E (Section 00 - General Information). To keep the vehicle interior looking the best, it should be cleaned often. It is important to keep the upholstery from becoming heavily soiled. The vehicle's interior can experience extreme heat, which can cause stains to set quickly. Lighter color interiors may require more frequent cleaning. Care should be taken because newspapers and garments may transfer color to the vehicle's interior. Many of today's interiors are made with new low gloss materials. Permanent damage may result from using cleaners on ANY surfaces (interior trim, instrument panel, carpet, leather, vinyl and fabric) for which they are not intended. Using non-approved products can actually set the stain to the point that nothing can remove it. Important Do not use silicone or wax-based products or those containing organic solvents (such as naptha, alcohol, etc.) to clean your vehicle's interior because they can alter the appearance by increasing the gloss in a non-uniform manner. The increase in gloss may cause annoying reflections in the windshield and even make it difficult to see through the windshield under certain conditions. - Never use a STIFF brush or a brush that has been previously used with a harsh chemical. This can cause damage to the vehicle's interior surfaces. - Use only mild, Neutral-pH cleaners. Avoid laundry detergents or dishwashing soaps with degreasers. Using too much soap will leave residue that leaves streaks and attracts dirt. Because it is critical to use only mild, neutral-pH cleaners, General Motors has approved the use of the cleaners and conditioners listed in this bulletin for the cleaning of interiors. These products are in the neutral-pH range and will maintain the best vehicle interior appearance. These products are water-based, biodegradable, and do not contain bleach, solvents or harsh chemicals. Interior trim pieces on new vehicles, as well as service components, arrive with a protective film. When removing the protective film, adhesive residue may be left on the trim panels/components. The cleaner (for leather, vinyl, plastic and interior paint) is an effective cleaner in removing adhesive residue without causing damage to the component. Important - If soapy, alkaline cleaning solutions are used on fabrics, and not thoroughly rinsed out, the residual left in the fabric will attract dirt. Because the recommended cleaners/conditioners are in the pH neutral range, they won't leave behind soapy residue. - On heavily stained or difficult to clean fabric/carpet, it is recommended that the entire surface be treated and cleaned vs. spot cleaning. Refer to Extractor Machine and Concentrate section of this bulletin for more information. Effective cleaning steps for hard and/or plastic surfaces: 1. Using a clean towel, apply/spray cleaner - leather, vinyl, plastic, interior paint, directly onto the towel. 2. Wipe the surface with the towel/cleaner. 3. If necessary, use a soft bristle brush to work cleaner into the crevasses of the area being cleaned. 4. Wipe off any excess cleaner from the surface. 5. Using a clean towel, apply/spray the conditioner (leather, vinyl restorer) directly onto the towel. 6. Wipe the conditioner onto the previously cleaned area to restore the material to it's original luster. Important Today's interiors are developed and intended to have a low-gloss appearance. It is important to use only products which provide a low-gloss finish in order to maintain the interior's integrity, customer appeal and satisfaction. Page 2069 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gauge at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Service and Repair Windshield Washer Switch: Service and Repair Windshield Wiper and Washer Switch Replacement Page 2949 Manifold Absolute Pressure (MAP) Sensor (LZ4 or LZE) Engine Controls - MIL ON/DTC P0172 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0172 Set TECHNICAL Bulletin No.: 10-06-04-004A Date: January 13, 2011 Subject: Intermittent Illumination of Malfunction Indicator Lamp (MIL)/Check Engine Light, DTC P0172 Set (Verify Alcohol Content Information in PCM) Models: 2010 Chevrolet Malibu Equipped with 2.4L 4 Cylinder Engine (VINs B, 0 - RPOs LE5, LE9) Please refer to GWM/IVH Supercede: This bulletin is being revised to update the engine type codes. Please discard Corporate Bulletin Number 10-06-04-004 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an intermittent illumination of the malfunction indicator lamp (MIL)/check engine light. Technicians may find a DTC P0172 set. Correction Use the procedure below to determine if the PCM has the incorrect alcohol content information. 1. Verify the actual measured percentage of alcohol content using the J-44175-A tester. Refer to Alcohol in Fuel Diagnosis in SI. If the actual alcohol is less than 15%, determine the "Fuel Alcohol Content" using the Tech 2(R). 2. Install the Tech 2(R) and build the vehicle as a 2010 and select Powertrain. 3. Build the vehicle with an LE9 engine (even if it has the LE5 engine). - Select Special Functions. - Select Fuel System (F2). Page 2443 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor. Installation Procedure Page 6907 14. Extract the steering gear oil seal (1) from the steering gear using the J 44586 remover/installer (2) with the aid of a flat-bladed tool (3) for additional leverage. Installation Procedure Note: Start all of the nuts and bolts by hand before finalizing any of the torques. 1. Install the NEW steering gear oil seal (1) to the steering gear using the J 44586 remover/installer (2). Page 5428 El - Ev Component Connector End Views Electric Power Steering (EPS) Module X1 (without NVH) Page 1801 10. Remove the EN 45680-881 fixture and EN 45680-883 cylinder bore sleeve installer assembly (1) from the cylinder block (2). Cylinder Liner Trimming * EN 45680-885 Debris Collector (3) * EN 45680-881 Trim Tool Assembly (2) * Air Control Valve (1) * Drill Motor with 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction Page 6365 Instrument Panel Cluster (IPC) Page 251 Page 5182 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Page 2897 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 9887 Page 5085 6. Remove the drive belt tensioner. 7. Remove the drive belt idler pulley bolt. 8. Remove the drive belt idler pulley. 9. Remove the generator bracket bolts. 10. Remove the generator bracket. Installation Procedure 1. Install the generator bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the generator bracket bolts and tighten in sequence to 50 Nm (37 lb ft). Page 10008 Page 9120 Service and Repair Compass: Service and Repair Instrument Cluster Replacement Page 2127 Installation Procedure 1. Install the heater core cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the heater core cover screws and tighten to 1.5 Nm (13 lb in). 3. Install the center floor air outlet duct. 4. Install the center floor air outlet duct screws and tighten to 1.5 Nm (13 lb in). 5. Install the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair). Page 9634 Page 6445 Wheel Speed Sensor (WSS) - Left Front Service and Repair Headliner: Service and Repair Headlining Trim Panel Replacement Page 4332 10. Connect the transaxle wiring harness to the following components: * TFP switch assembly * Pressure control solenoid (red connector) Note: The 1-2 shift solenoid wires are red and green. The 2-3 shift solenoid wires are red and yellow. * 1-2 shift solenoid * 2-3 shift solenoid * TCC solenoid 11. Install the oil pump shaft into the control valve body assembly. Note: If necessary, rotate the oil pump shaft while installing the oil pump assembly in order to engage the shaft splines to the splines on the oil pump rotor. 12. Install the oil pump assembly onto the oil pump shaft and the control valve body. Hand start and install the oil pump assembly bolts and tighten to 12 Nm (9 lb ft). 13. Install the transaxle case side cover. Refer to Control Valve Body Cover Replacement (See: Control Valve Body Cover Replacement). Page 2208 Installation Procedure 1. Install the catalytic converter (2) along with a NEW gasket to the exhaust manifold. 2. Position and join the exhaust pipe to the catalytic converter studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the catalytic converter to muffler nuts and tighten to 25 Nm (18 lb ft). 4. Install the catalytic converter to exhaust manifold nuts (1) and tighten to 45 Nm (33 lb ft). 5. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 2 (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor Replacement - Sensor 2). Page 4749 6. Remove the piston dust boot seal (2) from the seal counterbore in the caliper and discard the dust boot seal. 7. Using a small wooden or plastic tool, remove the piston seal from the caliper bore and discard the piston seal. 8. Inspect the operation of the integral park brake mechanism. Rotate the park brake lever back and forth while observing the movement of the park brake mechanism actuator assembly in the caliper bore. Note: The park brake lever, lever return spring and actuator shaft seal are not serviceable components of the integral park brake mechanism. Do not disassemble the integral park brake mechanism. 9. If the integral park brake mechanism was not operating properly (binding or seized), replace the brake caliper assembly. Installation Procedure Note: Do not use abrasives to clean the brake caliper piston. 1. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 2. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 3. Clean the brake caliper piston bore and seal counterbore, the caliper piston, and the caliper sleeves with denatured alcohol, or equivalent. 4. Dry the caliper piston bore and counterbore, the piston, and the sleeves with non-lubricated, filtered air. 5. Inspect the caliper piston for cracks, scoring, damage to the chrome plating, and/or damage to the integral adjusting mechanism. Replace the caliper piston if any of these conditions exist. 6. Inspect the caliper mounting holes for cracks, scoring, pitting, rust, and/or excessive corrosion. Replace the caliper assembly if any of these conditions exist. 7. Lubricate the new piston seal with GM approved or equivalent brake fluid from a clean, sealed brake fluid container. 8. Install the lubricated, new piston seal into the caliper bore. Page 6376 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LZ4 or LZE) Page 5481 Generator Battery 1 (-) (HP7) Generator Battery 1 (+) (HP7) Generator Battery 2 (-) (HP7) Generator Battery 2 (+) (HP7) Generator Battery 3 (-) (HP7) Page 6473 Audio Amplifier X3 (UQ3) Page 4393 15. Align the following items while latching: * The halfshaft inboard seal * The tripot housing (2) * The large seal retaining clamp (3)-Crimp the seal retaining clamp with J 35910 to 176 Nm (130 lb ft). Add the breaker bar (5) and the torque wrench (4) to J 35910 if necessary. 16. Check the gap dimension (a) on the clamp ear. If the gap dimension is larger than shown, continue tightening until the gap dimension of 2.6 mm (0.102 in) is reached. 17. Fully stroke the joint several times to disperse the grease. Page 1655 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 2947 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 4997 Parking Brake Release Switch: Diagrams Component Connector End Views Park Brake Switch Page 9363 9. With the aid of an assistant, remove the four bolts that secure the module to the roof ring. Lower and remove the sunroof module assembly out through the passenger side door. Installation Procedure 1. With the aid of an assistant, position the sunroof module assembly to the roof ring. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution) 2. Install the sunroof module bolts to the roof ring and tighten to 10 Nm (89 lb in). Page 6357 Inflatable Restraint Side Impact Module - Left Service and Repair Tail Light Bulb: Service and Repair Tail Lamp Bulb Replacement Page 3634 Shift Solenoid: Connector Views Component Connector End Views 1-2 Shift Solenoid (SS) Valve (ME7 or MN5) 2-3 Shift Solenoid (SS) Valve (ME7 or MN5) Page 9264 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Page 6296 Fog Lamp Switch (T96) Fuel Injector 1 (LAT or LE5 or LE9) Fuel Injector 1 (LY7) Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 2869 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 5595 Steering Wheel Position Sensor (NVH) Page 6736 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 3044 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 6429 Tail/Stop and Turn Signal Lamp - Left (LTZ) Page 851 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY7 or LZ4 or LZE) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LY7 or LZ4 or LZE) Page 10658 Front Door Window Glass: Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Page 10538 Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Page 1607 11. Using the tire machine, rotate the tire/wheel assembly clockwise when transferring the tire bead to the inside of the wheel rim. Ensure that the valve stem (1) is at the 7 o'clock position. 12. After the bottom bead is on the wheel, reposition the wheel and tire so that the valve stem (1) is at the 7 o'clock position relative to the head. This will protect the sensor while mounting the tire bead to the outside of the wheel. Page 5812 6. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals on to the bare wire using the J38125-7 crimp tool, jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 7. Position the wire seal to the terminal and crimp the seal and insulation using the J-38125-6 crimp tool, jaw 1 (1). The completed terminal and seal should appear as shown above (body harness connector shown). Note Avoid getting solder on the terminal end or overheating the terminal. Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. 8. Solder all four terminals at the wire crimp. 9. Slide the two body harness terminals through the opening of the orange connector position assurance (CPA) (1). Note A/T Controls - Downshift Hesitation/Delayed Shifting Rear Shelf: All Technical Service Bulletins Interior - Rear Shelf Foam Seal Is Loose TECHNICAL Bulletin No.: 09-08-110-001A Date: July 23, 2010 Subject: Loose Foam Seal Between Rear Window Shelf Trim Panel and Rear Glass (Replace Foam Seal) Models: 2008-2011 Chevrolet Malibu Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-110-001 (Section 08 - Body and Accessories). Condition Some customers may comment that the foam seal material between the rear window shelf trim panel (parcel shelf) and the rear glass is loose and exposed. Cause The foam anti-rattle seal may have been stretched when it was applied to the trim panel. Heat can cause the foam to shrink and the adhesive to fail, allowing the seal to separate from the trim panel. Correction Important DO NOT replace the rear window shelf trim panel for this condition. Use the following procedure to install a new foam seal. 1. Remove the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel in SI. 2. Remove the foam seal from the trim panel. 3. Clean any adhesive residue from the attaching surface on the trim panel using a general purpose adhesive cleaner. 4. Install a piece of Kent Industries P/N P46495*, 11 mm X 9 mm (3/8 in X 7/16 in) adhesive-backed pressure sensitive sponge rubber weatherstrip material, or the equivalent, on the trim panel in the location of the original foam seal. 5. Clean any adhesive residue from the rear window using a general purpose adhesive cleaner. 6. Reinstall the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel in SI. Page 2910 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 5075 7. Connect the body wiring harness electrical connector (1) to the ECM. 8. Position the body wiring harness UBEC electrical connectors (5) to the UBEC bracket and snap into place. 9. Position the forward lamp wiring harness UBEC electrical connector (4) to the UBEC bracket and snap into place. 10. Position the engine wiring harness UBEC electrical connector (3) to the UBEC bracket and snap into place. 11. Install junction block (2). 12. Tighten the junction block bolts (6) until the bolts engage the electrical connectors, an audible click will be heard. Tighten the bolts to 4 Nm (35 lb in). Page 5574 Seat Rear Vertical Motor - Passenger (LTZ) Seat Recline Motor - Driver (LTZ) Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Page 7826 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 1349 proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent, fluid tank valve, then disconnect the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent, from the J-35589-A - Master Cylinder Bleeder Adapter. 23. Remove the J-35589-A - Master Cylinder Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. Note: If it is determined that air was induced into the system upstream of the ABS modulator prior to servicing, the Antilock Brake System Automated Bleed (See: Antilock Brake System Automated Bleed) must be performed. 26. If the brake pedal feels spongy, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed (See: Antilock Brake System Automated Bleed). 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Brakes and Traction Control/Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Page 7030 Second Design - Black Painted (DO NOT Lube) Hydraulic Assist Power Steering First Design - Bare Steel Tube (Lube OK) Second Design - Black Painted (DO NOT Lube) In the unlikely event that the source of the noise is identified as a second design shaft with black painted tube, it must be replaced. Correction 1 (Only for First Design - DO NOT USE FOR 2ND DESIGN) Lubricate the intermediate shaft with steering column shaft lubrication kit, P/N 26098237. 1. From inside the vehicle, remove the instrument panel insulator panel - left side panel to gain access to the intermediate shaft. 2. Remove the intermediate shaft to steering column attachment bolt. 3. Remove the intermediate shaft from the steering column. 4. Extend the intermediate shaft all the way. Using the intermediate shaft grease kit, P/N 26098237, inject the grease into the gap between the inner shaft and the outer shaft as you are collapsing the shaft. This will draw the grease into the shaft. 5. Cycle the shaft up and down several times to distribute the grease. Important Remove original thread locker material from the bolt and apply Loctite(R) 242 (or equivalent) to the threads of the bolt and reinstall intermediate shaft bolt. 6. Install the intermediate shaft to the column. Tighten - For electronic power steering, tighten the bolt to 49 Nm (36 lb ft). - For hydraulic power steering, tighten the bolt to 62 Nm (46 lb ft). Page 9539 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Page 2573 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 9705 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 9002 Glove Compartment: Service and Repair Instrument Panel Compartment Door Latch Replacement Instrument Panel Compartment Door Latch Replacement Page 3798 Shift Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH2) Page 2765 Page 5545 Side Marker Lamp - Left Rear Side Marker Lamp - Right Front Side Marker Lamp - Right Rear Page 4166 Shifter A/T: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Procedures Carpet: Procedures Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications), may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. * Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a persistent or recurring odor, you may call to obtain additional information and usage suggestions. - In the USA, call 1-800-955-8591. - In Canada, call 1-800-977-4145. Floor Carpet Drying Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. * For a 1-piece carpet assembly with a separate cotton or a fiber padding, replace the cotton or fiber padding. While the carpet is out of the vehicle, dry the carpet using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Page 5716 X900 Decklid Jumper Harness to Decklid Harness Page 6048 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 8186 Page 9872 Page 8374 Garage Door Opener Transmitter: Testing and Inspection Garage Door Opener Inoperative Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The garage door opener (GDO) is a transmitter operating between 288 and 399 MHz. The GDO has three buttons that may be programmed for individual transmitter/receiver combinations to control up to three GDOs, security gates, lighting systems, etc. Each button represents a unique transmitter code section, which operates independently of the other buttons, and may be considered a separate transmitter. Reference Information Schematic Reference Remote Function Schematics (See: Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Transmitter/Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Garage Door Opener Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools J 41540 Universal Home Remote Tester Circuit/System Testing 1. Ignition OFF, disconnect the harness connector at the GDO. 2. Ignition OFF, test for less than 5 ohm between the ground circuit terminal 3 and ground. ‹› If greater than the specified value, test the ground circuit for an open/high resistance. 3. Ignition ON, verify a test lamp illuminates between the B+ circuit terminal 1 and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. Important: This step will clear any learned transmitters from the GDO. This will require reprogramming by the customer to reestablish GDO functionality. 4. Ignition ON, hold the two outer buttons on the GDO for 30 seconds. After 20 seconds, the LEDs will flash indicating that all learned transmitter values have been cleared. After an additional 10 seconds, the LEDs will flash again indicating it has entered the diagnostic mode. Place the J 41540 adjacent to the GDO and press each button of the GDO one at a time. The tester should indicate when each button is pressed. Page 4611 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transaxle case side cover. 2. Remove the TFP switch assembly bolts. 3. Remove the TFP switch assembly from the control valve body assembly. The TFP switch O-rings are reusable if not damaged and should remain with the switch assembly. Installation Procedure 1. Inspect the TFP switch assembly in order to verify the condition and correct location of the pressure switch O-rings. If necessary, replace the O-rings. Caution: Refer to Fastener Caution Page 5973 Page 8249 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 3006 Body Control Module (BCM) X3 Page 936 1 - Outside Rearview Mirror - Passenger 2 - Door Frame 3 - Door Latch - Passenger 4 - Inflatable Restraint Side Impact Sensor (SIS) - Right 5 - Window Switch - Passenger 6 - Speaker - Right Front 7 - Window Motor - Passenger 8 - Door Lock Switch - Passenger 9 - Courtesy Lamp - Right Front Door Interior - Rear Shelf Foam Seal Is Loose Rear Shelf: Customer Interest Interior - Rear Shelf Foam Seal Is Loose TECHNICAL Bulletin No.: 09-08-110-001A Date: July 23, 2010 Subject: Loose Foam Seal Between Rear Window Shelf Trim Panel and Rear Glass (Replace Foam Seal) Models: 2008-2011 Chevrolet Malibu Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 09-08-110-001 (Section 08 - Body and Accessories). Condition Some customers may comment that the foam seal material between the rear window shelf trim panel (parcel shelf) and the rear glass is loose and exposed. Cause The foam anti-rattle seal may have been stretched when it was applied to the trim panel. Heat can cause the foam to shrink and the adhesive to fail, allowing the seal to separate from the trim panel. Correction Important DO NOT replace the rear window shelf trim panel for this condition. Use the following procedure to install a new foam seal. 1. Remove the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel in SI. 2. Remove the foam seal from the trim panel. 3. Clean any adhesive residue from the attaching surface on the trim panel using a general purpose adhesive cleaner. 4. Install a piece of Kent Industries P/N P46495*, 11 mm X 9 mm (3/8 in X 7/16 in) adhesive-backed pressure sensitive sponge rubber weatherstrip material, or the equivalent, on the trim panel in the location of the original foam seal. 5. Clean any adhesive residue from the rear window using a general purpose adhesive cleaner. 6. Reinstall the rear window shelf trim panel. Refer to Rear Window Shelf Trim Panel in SI. Emissions - EVAP Damage Prevention On Vehicle Hoist Vehicle Lifting: Technical Service Bulletins Emissions - EVAP Damage Prevention On Vehicle Hoist INFORMATION Bulletin No.: 05-06-04-004E Date: May 29, 2009 Subject: Information to Avoid Damaging EVAP Canister and Setting DTCs P0442/P0455 When Hoisting Vehicle Models: 2004-2007 Chevrolet Malibu MAXX 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn AURA .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 05-06-04-004D (Section 06 Engine). .............................................................................................................................................................. .................................................................................. A review of warranty repair orders and parts returned to GM for analysis suggests that EVAP canisters are being damaged when the vehicle is being put up on a hoist for service. Incorrect placement of the hoist pads may cause a crack/leak in the EVAP canister plastic and eventually set one or both of the following DTCs: - DTC P0442 - small EVAP leak detected - DTC P0455 - large EVAP leak detected To avoid this situation, particularly when using the type of hoist where the arms swing in and the pick up pads swivel, be sure of the placement of the pick up pads. If the pick up pads are not positioned correctly to the underbody pick up areas, this type of damage may occur. Lifting Points (2008 Chevrolet Malibu Shown, Other Vehicles Similar) Lifting Pad Body Seam - DO NOT Lift Here EVAP Canister - DO NOT Lift Here For additional information and detail, refer to Lifting and Jacking the Vehicle in SI. Locations Horn Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 5339 Page 5690 X307 Inline Harness Connector End Views X307 PPS Module Harness to Passenger Heated Seat Harness (KA1) Page 10049 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to auto range to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Page 2806 Page 1102 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Page 1957 1. Use the J 35268-A in order to install the crankshaft front oil seal to the engine front cover. 2. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). Page 7296 Tires: Description and Operation All Seasons Tires Description All Seasons Tires Description This vehicle is equipped with steel belted all-season radial tires as standard equipment. These tires qualify as snow tires, with a higher than average rating for snow traction than the non-all season radial tires previously used. Other performance areas, such as wet traction, rolling resistance, tread life, and air retention, are also improved. This is done by improvements in both tread design and tread compounds. These tires are identified by an M + S molded in the tire side wall after the tire size. The suffix MS is also molded in the tire side wall after the TPC specification number. Service and Repair Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement Page 2759 Page 8061 Seat Belt Buckle: Service and Repair Rear Seat Buckle Side Belt Replacement Rear Seat Buckle Side Belt Replacement Page 850 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 10659 Disclaimer Exploded Views Shift Solenoid: Exploded Views 6T30/6T40/6T45 - Automatic Transmission Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly Page 1800 Caution: Do not use any air powered or electric tools to rotate the threaded shaft of the cylinder bore sleeve installer in the fixture assembly or damage to the cylinder bore sleeve will occur. 7. Using a ratchet, rotate the threaded shaft of EN 45680-88 fixture and EN 45680-883 cylinder bore sleeve installer assembly in order to install the cylinder bore sleeve into the engine block. 8. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1.60 mm (1/16 inch) of the cylinder bore sleeve above the surface of the cylinder block. 9. Using a torque wrench, tighten the threaded shaft of the EN 45680-881 fixture and EN 45680-883 cylinder bore sleeve installer assembly to 102 Nm (75 lb ft) in order to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore liner flange will protrude above the block deck surface. Page 4680 8. Connect the master cylinder primary brake pipe fitting (1) and tighten to 32 Nm (24 lb ft). 9. Connect the left brake pipe fitting (1) and tighten to 20 Nm (15 lb ft). Page 9679 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 6307 Generator X1 (LE5 or LE9) Page 9601 Page 5535 Inside Rearview Mirror (ISRVM) (DD7 or UE1 or 2LT) Page 5154 Page 1252 9. Remove the suction hose from the dash clip. 10. Remove the liquid line from the dash clip. 11. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 12. Remove the right front fender liner. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 13. Remove the right radiator air deflector retainers. 14. Remove the right radiator air deflector. 15. Remove the liquid line and compressor hose bolt from the condenser. 4T45-E - Automatic Transmission Shift Solenoid: Service and Repair 4T45-E - Automatic Transmission 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions See: Description and Operation. 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of Page 4804 Note: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in increased assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 1. Using the CH-42450-A - Wheel Hub Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the CH-41013 - Rotor Resurfacing Kit, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe. 8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Testing and Inspection/Brake Rotor Thickness Measurement). 11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. 12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner and wipe each friction surface using a clean shop towel to remove metal particles remaining from machining. Repeat the cleaning process if necessary to remove all metal particles. 13. Remove the brake rotor from the brake lathe. 14. Measure the assembled LRO of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout Measurement). 15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction (See: Testing and Inspection/Brake Rotor Assembled Lateral Runout Correction). Page 7346 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 9621 Page 2888 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 5982 Page 5738 Page 9516 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Page 4274 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Page 7882 1 - Outside Rearview Mirror - Passenger 2 - Door Frame 3 - Door Latch - Passenger 4 - Inflatable Restraint Side Impact Sensor (SIS) - Right 5 - Window Switch - Passenger 6 - Speaker - Right Front 7 - Window Motor - Passenger 8 - Door Lock Switch - Passenger 9 - Courtesy Lamp - Right Front Door Page 3289 5. Connect the chassis EVAP line quick connect fitting (2) to the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 6. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid valve (2). 7. Install the generator battery control module cover, if necessary. 8. Install the air cleaner outlet duct. Page 7762 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure Note: Refrigerant recovery is not required. 1. Remove the refrigerant pressure sensor wire harness connector. 2. Remove the refrigerant pressure sensor. 3. Remove and discard the O-ring. Installation Procedure 1. Install a new O-ring. Refer to Air Conditioning O-Ring Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning O-Ring Seal Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the refrigerant pressure sensor and tighten to 5 Nm (44 lb in). Page 407 Battery Control Module: Diagrams Component Connector End Views Generator Battery Disconnect Control Module X1 (LAT) Generator Battery Disconnect Control Module X2 (LAT) Page 3508 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 4042 Automatic Transmission/Control Valve Body Cover Replacement). 13. If a NEW TCM has been installed into the vehicle, the NEW module needs to be reprogrammed. Refer to Service Programming System (SPS) ( See: Testing and Inspection/Programming and Relearning/Service Programming System (SPS)). Note: The Service Fast Learn Adapts procedure must be performed when one of the following repairs have been made to the vehicle. Failure to perform the procedure after one of the following repairs may result in poor transmission performance, as well as transmission DTCs being set: * Transmission internal service/overhaul * Valve body repair or replacement * Control solenoid valve assembly replacement * TCM software/calibration update * Any service in response to a shift quality concern 14. Perform the Service Fast Learn Adapts. Refer to Service Fast Learn Adapts (See: Testing and Inspection/Programming and Relearning/6T70/6T75 - Automatic Transmission). Wheels/Tires - Use of Nitrogen Gas in Tires Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Page 6893 Assembly Procedure 1. Lubricate the NEW power steering fluid reservoir O-ring seal with power steering fluid and install it onto the neck of the power steering fluid reservoir. 2. Install the power steering fluid reservoir to the power steering pump. 3. Press the power steering fluid reservoir into the power steering pump until the neck is completely engaged. 4. Align the feet of the power steering fluid reservoir with the sides of the power steering pump. 5. Install the 2 power steering fluid reservoir retaining clips. Ensure the power steering fluid reservoir retaining clip tabs fully engage with the power steering pump. 6. Install the power steering pump. Refer to Power Steering Pump Replacement (See: Power Steering Pump/Service and Repair/Power Steering Pump Replacement). Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal Assembly Replacement Removal Procedure 1. Remove the knee bolster. Refer to Driver Knee Bolster Panel Replacement (See: Restraint Systems/Knee Diverter/Service and Repair). 2. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 3. Disconnect the electrical connector from the brake apply sensor. 4. Remove the steering column assembly from the vehicle. Refer to Steering Column Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Replacement). 5. Disconnect the brake pedal pushrod retaining clip (1) the wave washers (2) and the brake booster pushrod (3) from the brake pedal pin (4). 6. Remove the 2 brake pedal assembly to cowl mounting nuts. Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement Inflatable Restraint Front End Sensor Replacement Page 240 Relay Box: Locations Fuse Block - Rear Electrical Center Identification Views Fuse Block - Rear Label Page 887 Page 6793 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Page 6448 Window Motor - Driver (without AXG or LTZ) Page 9564 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close Page 9913 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Page 5591 Starter Generator Control Module (SGCM) X4 (LAT) Starter Generator Control Module (SGCM) X5 (LAT) Starter Generator Control Module (SGCM) X6 (LAT) Starter Generator Control Module (SGCM) Coolant Pump (LAT) OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 5444 Page 1386 Body Control Module (BCM) Top View Page 2844 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Page 6124 * Use TXL type wire Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9794 Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster and Recliner Switch Replacement Driver or Passenger Seat Adjuster and Recliner Switch Replacement Page 8984 Front Floor Console Bracket Replacement Front Floor Console Bracket Replacement Page 4760 Note: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 3. Install the brake pads (2) to the caliper bracket. 4. Remove the support (1), and rotate the brake caliper into position over the disc brake pads and to the caliper mounting bracket. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the lower brake caliper guide pin bolt (1) and tighten to 35 Nm (26 lb ft). 6. Remove the wheel nuts retaining the brake rotor to the hub. 7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. Lower the vehicle. 9. With the engine OFF, gradually apply the brake pedal approximately 2/3 of its travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then gradually apply the brake pedal approximately 2/3 of its travel distance again until a firm brake pedal apply is obtained. This will properly seat the brake caliper pistons and brake pads. Page 6154 Steering Linkage Inner Tie Rod Replacement Tie Rod: Service and Repair Steering Linkage Inner Tie Rod Replacement Steering Linkage Inner Tie Rod Replacement Special Tools J-34028 - Inner Tie Rod Wrench Disassembly Procedure 1. Remove the steering gear from the vehicle. Refer to Steering Gear Replacement (See: Steering Gear/Service and Repair/Steering Gear Replacement). Note: After removing the boots, inspect the inner tie rod for evidence of corrosion or contamination. If none is evident, continue with the repair. If corrosion or contamination is evident, replace the steering gear. 2. Remove the 2 steering gear boots. Refer to Steering Gear Boot Replacement (See: Steering Gear/Service and Repair/Steering Gear Boot Replacement). 3. Place the steering gear in a vise. Caution: Do not change the steering gear preload adjustment before moving the inner tie rod from the steering gear. Changing the steering gear preload adjustment before moving the inner tie rod could result in damage to the pinion and the steering gear. 4. Slide the left shock dampener (4) from the left inner tie rod housing (6) to the rack (5). Caution: The pipe wrench must be placed at the valve end of the steering gear and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear. 5. Place a pipe wrench on the rack next to the left inner tie rod housing. 6. Place a wrench on the flats of the left inner tie rod housing. 7. Rotate the left inner tie rod housing counterclockwise, while holding the rack stationary, until the left inner tie rod separates from the rack. 8. Slide the right shock dampener (3) from the right inner tie rod housing (2) to the rack (5). 9. Place a pipe wrench on the left side of the rack. 10. Place a wrench on the flats of the right inner tie rod housing. 11. Rotate the right inner tie rod housing counterclockwise, while holding the rack stationary, until the right inner tie rod (1) separates from the rack. Locations Steering Control Module: Locations Instrument Panel/Center Console Component Views Instrument Panel Components - Steering Column 1 - Inflatable Restraint Steering Wheel Module Coil 2 - Power Steering Control Module (PSCM) 6T30/6T40/6T45 - Automatic Transmission Transmission Speed Sensor: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Output Speed Sensor Replacement Output Speed Sensor Replacement Input Speed Sensor Replacement Input Speed Sensor Replacement Removal Procedure 1. Remove the transmission control valve body cover. Page 250 Page 1602 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. Consult your repair material supplier for the proper stitching tool. Safety Cage Some run flat tires may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection Page 1276 14. Extract the steering gear oil seal (1) from the steering gear using the J 44586 remover/installer (2) with the aid of a flat-bladed tool (3) for additional leverage. Installation Procedure Note: Start all of the nuts and bolts by hand before finalizing any of the torques. 1. Install the NEW steering gear oil seal (1) to the steering gear using the J 44586 remover/installer (2). Page 8005 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 2691 Repair/Cooling System Draining and Filling). Page 2216 16. Connect the engine wiring harness electrical connector (4) to the HO2S electrical connector (3). 17. Install the CPA retainer (5). 18. Install the HO2S electrical connector rosebud clip to the oil level indicator tube tab. 19. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). Page 8635 Page 8175 Locations Fuel Pump Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 1397 Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 5628 Yaw and Lateral Accelerometer Sensor Page 5309 FUSE PULLER .................................................................................................................................... ............................................................ Fuse Puller Page 3464 Page 3539 Page 6285 Engine Control Module (ECM) X3 (LAT) A/T Controls - Downshift Hesitation/Delayed Shifting Control Module: All Technical Service Bulletins A/T Controls - Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6174 Fuse Block - Rear Bottom View Page 7152 8. Firmly align the lower spring coil in the spring seat pocket. 9. Place the upper spring insulator and spring seat onto the top of the coil spring. 10. Place the bearing and strut mount on the top of the spring seat. Page 2882 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors Yazaki Connectors Special Tools J-38125 Terminal Repair Kit Page 3078 4. Connect the body wiring harness electrical connector (1) to the ECM. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 6. Program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Page 8601 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 5065 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (LAT or LE5 or LY7 or LE9) Page 5344 Fuse Block - Rear Top View Page 743 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 976 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Specifications Compression Check: Specifications Engine Compression Test The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). Page 5321 Body Control Module (BCM) X3 Page 10113 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Page 9562 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 3431 4. Lubricate the NEW fuel injector tip insulators with clean engine oil. 5. Install the NEW fuel injector tip insulators to the cylinder head. 6. Lubricate the fuel injector O-rings with clean engine oil. 7. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports. 8. Carefully push down on the fuel rail in order to insert the injectors into the cylinder head ports. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the fuel rail bolts and tighten to 10 Nm (89 lb in). Page 3976 Auxiliary Fluid Pump Outlet Pipe Replacement Auxiliary Fluid Pump Outlet Pipe Replacement Page 557 Page 9358 1. Feed the rear sunroof drain hose down the C-pillar through the outboard access hole in the rear package shelf and into the rear compartment. 2. Connect the rear sunroof drain hose to the sunroof drain spigot. 3. Connect the drain hose to the attachment clips on the roof rail, the C-pillar, and the rear compartment. 4. Install the grommet into the opening in the rear lower quarter panel, if necessary. Ensure that the grommet is fully seated. 5. Connect the end of the drain hose to the grommet. 6. Install the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Compartment Trim Panel Replacement). 7. Install the headliner. Refer to Headlining Trim Panel Replacement (See: Interior Moulding / Trim/Headliner/Service and Repair). 8. Close the rear compartment. Page 5007 Traction Control Switch: Service and Repair Electronic Traction Control Switch Replacement Page 5353 Locations Transmission Position Switch/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components (ME7 or MN5) 1 - Park/Neutral Position (PNP) Switch Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) Page 10022 Page 5686 X217 Inline Harness Connector End Views X217 Body Harness to DVD Power Jumper Harness (SPO Accessory) Page 3119 Page 1239 3. Install the heater inlet hose to the heater core. 4. Reposition the heater inlet hose clamp at the heater core using the J 38185. 5. Install the surge tank to the surge tank bracket. 6. Fill the coolant. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). Page 9741 Seat Heater Switch: Service and Repair Driver or Passenger Seat Heater Switch Replacement Page 7530 Page 3233 Page 8623 Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Replacement Brake Pedal Position Sensor Replacement Locations Oil Pressure Sender: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) Locations Impact Sensor: Locations SIR Identification Views The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure, refer to SIR Disabling and Enabling (See: Air Bag(s) Arming and Disarming/Service and Repair). Malibu or Maxx 1 - Right Front Impact Sensor-Located under the hood at the front right side of the vehicle 2 - Front Hood Assist Rod-A gas shock located under the front hood on the passenger side 3 - Passenger Instrument Panel Air Bag-Located at the top right under the instrument panel 4 - Right Roof Rail Air Bag-Located under the headliner, extending from the passenger front windshield pillar to the passenger rear windshield pillar 5 - Right Front Side Impact Sensor (SIS)-Located behind door panel on the passenger front door 6 - Inflatable Restraint Sensing and Diagnostic Module (SDM)-Located underneath the vehicle carpet under the center console 7 - Passenger Seat Side Air Bag-Located on the seat back of passenger seat 8 - Passenger Seat Belt Retractor Pretensioner-Located under the trim near the bottom of the center pillar on the passenger side of vehicle 9 - Inflator Module for Right Roof Rail Air Bag-Located behind the garnish molding on the upper rear pillar 10 - Rear Hood Assist Rod-A gas shock located under the rear truck lid on the passenger side 11 - Rear Hood Assist Rod-A gas shock located under the rear truck lid on the driver side 12 - Inflator Module for Left Roof Rail Air Bag-Located behind garnish molding on the upper rear pillar 13 - Driver Seat Belt Retractor Pretensioner-Located under the trim near the bottom of the center pillar on the driver side of vehicle 14 - Driver Seat Side Air Bag-Located on the seat back of driver seat 15 - Left Front Side Impact Sensor (SIS)-Located behind door panel on the driver front door 16 - Left Roof Rail Air Bag-Located under the headliner, extending from the driver front windshield pillar to the driver rear windshield pillar 17 - Driver Steering Wheel Air Bag-Located on the steering wheel 18 - Front Hood Assist Rod-A gas shock located under the front hood on the driver side 19 - Vehicle Battery-Located at the front left of the engine compartment 20 - Left Front Impact Sensor-Located under the hood at the front left side of the vehicle Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (1 of 2) Page 10043 Locations Hood Sensor/Switch (For Alarm): Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (2 of 2) 1 - Hood Ajar Switch (AP3) Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Page 1969 Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 6377 Mode Actuator Page 3310 10. Install the right rear frame reinforcement (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 11. Install the right rear frame bolts (4) and tighten to 100 Nm (74 lb ft) plus an additional 90 degrees using the J 45059. 12. Lower the vehicle. 13. Install the brake pipes to the clips. 14. Install the brake, fuel, and EVAP pipe clips (1, 2) to the studs on the front of dash. Service and Repair Windshield Washer Switch: Service and Repair Windshield Wiper and Washer Switch Replacement Service and Repair Turn Signal Bulb: Service and Repair Parking and Turn Signal Lamp Bulb Replacement Page 2966 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY7 or LZ4 or LZE) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LY7 or LZ4 or LZE) Page 49 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 8360 Digital Video Disc (DVD) Control Module X5 (SPO Accessory) (UJ5) Page 2753 Page 9650 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Service and Repair Piston: Service and Repair Piston, Connecting Rod, and Bearing Replacement Special Tools * EN-8037 - Ring Compressor * EN-24270 - Cylinder Bore Ridge Reamer * EN-43966-1 - Connecting Rod Guides * EN-45059 - Angle Meter For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the oil pan. Refer to Oil Pan Replacement (See: Engine Lubrication/Oil Pan/Service and Repair). 2. Remove the cylinder head. Refer to Cylinder Head Replacement (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement ). 3. If a ring ridge is present, remove the ring ridge as follows: 1. Turn the crankshaft until the piston is at the bottom of the stroke. 2. Place a cloth on top of the piston. 3. Use a EN-24270 - reamer to remove the ring ridge. 4. Turn the crankshaft so the piston is at top of the stroke. 5. Remove the cloth and cutting debris. Note: Place the numbers on connecting rods and the connecting rod caps. The connecting rod caps must be assembled to their original connecting rods. Page 3308 12. Disconnect the fuel tank fuel feed pipe quick connect fitting (1) from the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 13. Disconnect the fuel tank EVAP pipe quick connect fitting (2) from the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 14. Cap the chassis fuel and EVAP pipes in order the prevent possible fuel and/or EVAP system contamination. 15. Remove the brake, fuel and EVAP pipe retainers (5) from the underbody studs. 16. Remove the brake pipes from the retainers. 17. Remove the fuel feed/EVAP pipe assembly from the vehicle. 18. Place the pipe assembly on a work bench. 19. Open and remove the upper fuel feed/EVAP pipe retainer (3). 20. Open and remove the front of dash fuel feed/EVAP pipe retainers (4). 21. Open and remove the underbody retainers (5). 22. Replace any retainers as necessary. Installation Procedure Page 4907 4. Install the master cylinder to the vacuum brake booster. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the 2 brake master cylinder mounting nuts and tighten to 25 Nm (18 lb ft). 6. Install the brake pipes to the master cylinder and tighten the brake pipe fittings to 32 Nm (24 lb ft). 7. Connect the electrical connector to the brake fluid level sensor. Page 4055 Seals and Gaskets: Service and Repair 6T70/6T75 - Automatic Transmission Front Wheel Drive Shaft Seal Replacement - Left Side Front Wheel Drive Shaft Seal Replacement - Left Side Front Wheel Drive Shaft Seal Replacement - Right Side Front Wheel Drive Shaft Seal Replacement - Right Side Page 10048 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Radio Front Side Door Lower Speaker Replacement Speaker: Service and Repair Radio Front Side Door Lower Speaker Replacement Radio Front Side Door Lower Speaker Replacement Page 7076 Axle Beam: Service and Repair Rear Axle Control Trailing Arm and Rear Suspension Control Arm Bracket Replacement Rear Axle Control Trailing Arm and Rear Suspension Control Arm Bracket Replacement Special Tools J 45059 Angle Meter Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the park brake cable retaining bolt (3) and the bracket (1) from the trailing arm (3). Page 6916 7. Install the 2 power steering gear outlet pipe hose retainers (1) to the right side of the front frame. 8. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 9. Compress the power steering gear outlet hose clamp (1) and connect the power steering gear outlet hose (3) to the power steering reservoir inlet pipe (2). 10. Clean any excess power steering fluid from the vehicle and remove the drain pans. 11. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). 12. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering Bleeding/Service and Repair). Page 10000 Capacity Specifications Engine Oil: Capacity Specifications Engine Oil with Filter ............................................................................................................................ ............................................... 5.0 quarts (4.7 liters) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Front Side Marker Lamp Bulb Replacement Marker Lamp Bulb: Service and Repair Front Side Marker Lamp Bulb Replacement Front Side Marker Lamp Bulb Replacement Page 6191 threads. 5. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 6. Install the electrical ground terminal to the new, conductive M7 bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the M7 bolt and tighten to 9 Nm (80 lb in). 8. Check for proper system operation. M6 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a conductive M6 bolt and a conductive M6 nut may be used to secure the electrical ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 ) clearance behind the panel surface and 20 mm (0.79 ) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M6 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M6 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). Note: The repair area must be properly refinished to maintain positive electrical grounding. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a conductive M8 bolt and a conductive M8 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent to M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M8 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M8 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M8 nut and tighten to 22 Nm (16 lb ft). Note: The repair area must be properly refinished to maintain positive electrical grounding. Page 6415 Speaker - Right Rear (UW5) Starter Generator X1 (KY1) Page 6300 Fuel Injector 3 (LZ4 or LZE) Page 4106 Automatic Transmission Output Shaft Speed (OSS) Sensor (ME7 or MN5) Page 10758 Washer Fluid Level Switch: Diagrams Component Connector End Views Windshield Washer Fluid Level Switch Page 7674 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the liquid line bracket bolt and tighten to 10 Nm (89 lb in). 5. Install the refrigerant pressure sensor wire harness connector. 6. Install the line clip to the dash. 7. Install the suction hose to the dash clip. 8. Install the suction hose and liquid line to the TXV. 9. Install the suction hose and liquid line nut to the TXV and tighten the nut to 20 Nm (15 lb ft). 10. Install new O-rings. Refer to Air Conditioning O-Ring Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning O-Ring Seal Replacement). 11. Install the suction hose to the compressor hose. Locations Knock Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Lower Front and Rear of the Engine Components (LY7) Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (without LAT or HP7) 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 7819 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the SIR circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Page 5811 3. Disconnect the seat to body harness connector (1). Disconnect the seat airbag connector (2). Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing into the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Slide the conduit away on the seat airbag harness and remove just enough tape on the body harness to access the wires to install the terminals and seals. Note Use caution when stripping insulation. Take care not to cut through the wire strands. 5. Slide the wire seals onto all four leads back enough to enable removal of the insulation. Install the blue seals (1) on the body harness and the white seals (2) on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Page 2892 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. Page 10312 For vehicles repaired under warranty use the table above. Disclaimer Page 5071 6. Loosen the junction block bolts (6), once loose, tap the bolts once in order the disengage the bolts from the electrical connectors. 7. Remove the junction block (2). Note: Note the color and location of each electrical connector. 8. Remove the engine wiring harness UBEC electrical connector (3) from the UBEC bracket and secure out of the way. 9. Remove the forward lamp wiring harness UBEC electrical connector (4) from the UBEC bracket and secure out of the way. 10. Remove the body wiring harness UBEC electrical connectors (5) from the UBEC bracket and secure out of the way. 11. Disconnect the body wiring harness electrical connector (1) from the engine control module (ECM). Page 5518 Ignition Coil 5 (LY7) Page 4542 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Front of the Transmission Components (MH2 or MH8) Page 9630 Page 8986 Front Floor Console Compartment Replacement Front Floor Console Compartment Replacement Driver or Passenger Seat Head Restraint Guide Replacement Head Rest: Service and Repair Driver or Passenger Seat Head Restraint Guide Replacement Driver or Passenger Seat Head Restraint Guide Replacement Steering - Front End Clunk/Rattle/Knock On Bumps Steering Gear: All Technical Service Bulletins Steering - Front End Clunk/Rattle/Knock On Bumps TECHNICAL Bulletin No.: 06-02-32-007G Date: April 05, 2010 Subject: Clunk, Knock or Rattle Noise From Front of Vehicle While Driving or Turning Over Bumps at Low Speeds (Diagnose Noise and Perform Outlined Repair) Models: 2004-2006 Chevrolet Malibu Maxx 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn Aura Supercede: This bulletin is being revised to update the Parts Information for the bolt. Please discard Corporate Bulletin Number 06-02-32-007F (Section 02 - Steering). Condition 1 Some customers may comment on a clunk noise heard and felt in the steering wheel while driving at slow speeds and turning. The clunk noise may appear to be directly in front of the driver. Hitting a bump while turning can produce the clunk noise. Sometimes the noise may be duplicated when the vehicle is sitting still and the steering wheel is turned 90 degrees in either direction before initially centering the steering wheel. Cause 1 The clunk noise may be caused by a slip/stick condition between the inner and outer components of the intermediate shaft. Important Revised design intermediate shafts went into production in the 2009 model year and are the only design currently available through GMSPO since approximately September 2008. Since any model year vehicle could have had a second design shaft installed, it is critical to identify it before proceeding. The revised design intermediate shafts will NOT tolerate any type of lubricant per the following instructions. Adding lube to the second design shafts will cause a clunk noise in a very short period of time. Use the following pictures to identify which design of shaft you are servicing. Electric Assist Power Steering First Design - Bare Steel Tube (Lube OK) Page 1232 Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Pipe Replacement Engine Coolant Air Bleed Pipe Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Fuel Injector Sight Shield Replacement (). 2. Remove the surge tank inlet hose. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement (See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Radiator Surge Tank Inlet Hose/Pipe Replacement). 3. Remove the fuel feed pipe line nut (2). 4. Remove the fuel feed line clip from the stud and reposition the fuel feed line. 5. Remove the coolant air bleed hose/pipe bolt (3) from the upper intake manifold. 6. Reposition the coolant air bleed hose clamp (2) at the water outlet. 7. Remove the coolant air bleed hose from the water outlet. Locations Brake Booster Vacuum Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Page 4372 7. Remove the spacer ring (1), spider assembly (2), spacer ring (3) (if equipped) using J 8059, and tripot boot (4). Discard the boot and rings. 8. Clean the halfshaft bar (5). Use a wire brush in order to remove any rust in the boot mounting area (grooves). 9. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit. Installation Procedure Note: Place a towel in the vise before inserting the halfshaft. 1. Mount the halfshaft into a vise. 2. Place the new small eared clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the eared clamp (2) onto the halfshaft bar. 3. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar. A/T Controls - Downshift Hesitation/Delayed Shifting Control Module: All Technical Service Bulletins A/T Controls - Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 8014 Air Bag Control Module: Locations SIR Identification Views The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure, refer to SIR Disabling and Enabling (See: Air Bag Systems/Air Bag(s) Arming and Disarming/Service and Repair). Malibu or Maxx 1 - Right Front Impact Sensor-Located under the hood at the front right side of the vehicle 2 - Front Hood Assist Rod-A gas shock located under the front hood on the passenger side 3 - Passenger Instrument Panel Air Bag-Located at the top right under the instrument panel 4 - Right Roof Rail Air Bag-Located under the headliner, extending from the passenger front windshield pillar to the passenger rear windshield pillar 5 - Right Front Side Impact Sensor (SIS)-Located behind door panel on the passenger front door 6 - Inflatable Restraint Sensing and Diagnostic Module (SDM)-Located underneath the vehicle carpet under the center console 7 - Passenger Seat Side Air Bag-Located on the seat back of passenger seat 8 - Passenger Seat Belt Retractor Pretensioner-Located under the trim near the bottom of the center pillar on the passenger side of vehicle 9 - Inflator Module for Right Roof Rail Air Bag-Located behind the garnish molding on the upper rear pillar 10 - Rear Hood Assist Rod-A gas shock located under the rear truck lid on the passenger side 11 - Rear Hood Assist Rod-A gas shock located under the rear truck lid on the driver side 12 - Inflator Module for Left Roof Rail Air Bag-Located behind garnish molding on the upper rear pillar 13 - Driver Seat Belt Retractor Pretensioner-Located under the trim near the bottom of the center pillar on the driver side of vehicle 14 - Driver Seat Side Air Bag-Located on the seat back of driver seat 15 - Left Front Side Impact Sensor (SIS)-Located behind door panel on the driver front door 16 - Left Roof Rail Air Bag-Located under the headliner, extending from the driver front windshield pillar to the driver rear windshield pillar 17 - Driver Steering Wheel Air Bag-Located on the steering wheel 18 - Front Hood Assist Rod-A gas shock located under the front hood on the driver side 19 - Vehicle Battery-Located at the front left of the engine compartment 20 - Left Front Impact Sensor-Located under the hood at the front left side of the vehicle Passenger Compartment/Roof Component Views Roof/Headliner and Under the Center Console Components Page 10112 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 2140 Heater Hose: Service and Repair Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement Page 2406 1. Install the MAF/IAT sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1) and tighten to 2.5 Nm (22 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor (2). Page 2877 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 2244 Exhaust Pipe: Service and Repair Exhaust Pipe Replacement Exhaust Pipe Replacement Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the exhaust pipe to muffler nuts. 3. Remove the exhaust pipe to right catalytic converter nuts. Brake Pressure Modulator Valve Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Replacement Brake Pressure Modulator Valve Replacement Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Clean the brake pressure modulator valve (BPMV) pipe fitting areas of any accumulated dirt and foreign material. 3. Disconnect the electrical connector from the electronic brake control module (EBCM). 4. Place a shop towel under the BPMV to catch any brake fluid loss. 5. Disconnect the RF brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Page 4278 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). 6. Remove the alignment tool. Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 7. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Locations Hazard Warning Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 9447 Effective cleaning steps for fabric: 1. Remove any residue by lightly rubbing the surface with a clean towel. 2. Choose the appropriate stain remover based on the stain type. 3. Spray and lightly brush the area with a clean, soft bristle brush. 4. Gently blot up the stain. 5. On upholstery/carpet, the use of a fabric protector can help to reduce or eliminate future staining. Upholstery and Carpet Stains When cleaning upholstery and carpet stains ONLY, the following cleaning chart will help you determine which cleaner/formula works best on a particular stain. The chart lists many of the common stains. Some complex stains may require the application of both stain removers, one after the other, to remove both food-based oils and synthetic oils. A soft bristle brush (P/N 88861425) should be used to safely work the cleaner into the leather grain or material. This enables the dirt/stain to be completely removed from the material. Leather Conditioner/Restorer A Leather Conditioner/Restorer is also available. The restorer is safe for all vinyl and leather. It is a water-based product and contains essential emollients to restore suppleness, conditions and adds luster without adding gloss. The restorer will also provide protection against re-staining. Page 2169 Page 2113 Page 10426 Page 280 Body Control Module (BCM) X2 Page 7843 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the SIR circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Page 7258 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage Page 5971 Page 3971 Fluid Pump: Diagrams Component Connector End Views Automatic Transmission Auxiliary Fluid Pump (HP7 with ME7) Automatic Transmission Auxiliary Fluid Pump Control Module (HP7 with ME7) Engine Controls - MIL ON/DTC P0172 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0172 Set TECHNICAL Bulletin No.: 10-06-04-004A Date: January 13, 2011 Subject: Intermittent Illumination of Malfunction Indicator Lamp (MIL)/Check Engine Light, DTC P0172 Set (Verify Alcohol Content Information in PCM) Models: 2010 Chevrolet Malibu Equipped with 2.4L 4 Cylinder Engine (VINs B, 0 - RPOs LE5, LE9) Please refer to GWM/IVH Supercede: This bulletin is being revised to update the engine type codes. Please discard Corporate Bulletin Number 10-06-04-004 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an intermittent illumination of the malfunction indicator lamp (MIL)/check engine light. Technicians may find a DTC P0172 set. Correction Use the procedure below to determine if the PCM has the incorrect alcohol content information. 1. Verify the actual measured percentage of alcohol content using the J-44175-A tester. Refer to Alcohol in Fuel Diagnosis in SI. If the actual alcohol is less than 15%, determine the "Fuel Alcohol Content" using the Tech 2(R). 2. Install the Tech 2(R) and build the vehicle as a 2010 and select Powertrain. 3. Build the vehicle with an LE9 engine (even if it has the LE5 engine). - Select Special Functions. - Select Fuel System (F2). Page 6029 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 3004 Body Control Module (BCM) X2 Page 5086 3. Install the drive belt tensioner. 4. Install the drive belt tensioner bolt and tighten to 50 Nm (37 lb ft). 5. Install the drive belt idler pulley. 6. Install the drive belt idler pulley bolt and tighten to 50 Nm (37 lb ft). 7. Install the generator. Refer to Generator Replacement (See: Generator Replacement). 8. Rotate the drive belt tensioner counterclockwise. 9. Install the accessory drive belt. Refer to Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Accelerator Pedal with Position Sensor Assembly Replacement Accelerator Pedal: Service and Repair Accelerator Pedal with Position Sensor Assembly Replacement Accelerator Pedal with Position Sensor Assembly Replacement Removal Procedure 1. Disconnect the accelerator pedal position (APP) sensor electrical connector. 2. Remove the APP sensor bolts (1). 3. Remove the APP sensor (2). Installation Procedure 1. Install the APP sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Page 4092 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Electronic Components (MH8) Page 5471 Fuel Injector 3 (LZ4 or LZE) Page 6752 Disclaimer Page 6812 Alignment: Testing and Inspection Trim Height Inspection Trim Height Measurement Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause the vehicle to bottom out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Set the tire pressure to the specifications shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). * Check the fuel level. Add additional weight if necessary to simulate a full tank. * Make sure the passenger and rear compartments are empty, except for the spare tire. * Make sure the vehicle is on a flat and level surface, such as an alignment rack. * Check that all the vehicle doors are securely closed. * Check that the vehicle hood and rear deck lids are securely closed. * Check for installed after market accessories or modifications that could affect trim height measurement. Measuring the P and R Dimension Important: All dimensions are measured vertical to the ground. Trim height should be within ±10 mm (±0.39 in) to be considered correct. Use the following procedure to check the P and R dimensions: 1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let the vehicle settle. 3. Repeat this operation 2 more times for a total of 3. 4. P height is measured vertically from the ground to the bottom lip of the wheel opening through the centerline of the front wheel. 5. Push the front bumper of the vehicle down about 38 mm (1.5 in). 6. Gently remove your hands and let the vehicle settle down. 7. Repeat this operation 2 more times for a total of 3. 8. Measure the P height as in step 4. 9. The true P height measurement is the average of the measurements taken in step 4 and 8. 10. Repeat the above steps on the rear of the vehicle for the R heights Measuring the Z Dimension Page 1419 Page 6380 Outside Rearview Mirror Switch Park Brake Switch Page 9701 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (without LAT or HP7) 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 5486 Generator Battery Vent Fan (HP7) Ha - He Page 3369 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Page 1783 2. Install the piston into its original bore using the EN-43966-1 - guides. 3. Lightly tap the top of the piston with a wooden hammer handle. 4. When installing the piston and the connecting rod, the stamped mark on the piston must point to the front of the engine. 5. Hold the EN-8037 - compressor firmly against the engine block until all the piston rings have entered the cylinder bore. 6. Install the connecting rod caps onto their original connecting rods. 7. Align the numbers placed on the connecting rod and the connecting rod cap during removal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the new connecting rod bolts and nuts. * On the first pass, tighten the nuts evenly to 25 Nm (18 lb ft). * On the final pass, use the EN-45059 - meter in order to tighten the nuts an additional 100 degrees. 9. Measure the connecting rod side clearance with a feeler gauge. The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in). 10. Install the cylinder head. Refer to Cylinder Head Replacement (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement). 11. Install the oil pan. Refer to Oil Pan Replacement (See: Engine Lubrication/Oil Pan/Service and Repair). Page 8103 Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Front End Sensor - Left Inflatable Restraint Front End Sensor - Right Inflatable Restraint Side Impact Sensor (SIS) - Left Page 142 Installation Procedure 1. Clean the sealing surface of the BPMV with denatured alcohol and a clean shop cloth. 2. Carefully install the EBCM (1) to the BPMV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the 4 EBCM bolts (1). Tighten the bolts in a cross pattern to 3 Nm (27 lb in). Note: Ensure the electrical connector is correctly inserted into the EBCM prior to placing the locking lever into position. Failure to make a proper connection may cause communication problems with the module. 4. Connect the electrical connector to the EBCM. 5. If installing a new EBCM, it is necessary to program the EBCM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). A/C - Poor Cooling Performance/Condenser Fan Fuse Blown Fuse: Customer Interest A/C - Poor Cooling Performance/Condenser Fan Fuse Blown TECHNICAL Bulletin No.: 09-01-38-005 Date: October 09, 2009 Subject: Poor A/C Performance, Cooling Fan Fuse Blown (Install Revised Fuse And Wiring) Models: 2008-2010 Chevrolet Malibu 2006-2010 Pontiac G6 2007-2010 Saturn AURA All with RPO LY7, LZ4, LZ9 or LZE V6 Engine Condition Some customers may comment on poor A/C cooling performance. Technicians may find that the cooling fan fuse is blown. Cause High cooling fan start up loads may cause the 30-amp cooling fan fuse, located in the underhood fuse block, to blow. The lack of air flow through the A/C condenser, caused by the inoperative high-speed cooling fan, may affect the condenser's ability to dissipate heat. Correction Use the following procedure to install a heavier gauge power feed wire from the underhood fuse block to the cooling fan. After the wiring update is completed, replace the 30-amp cooling fan fuse in the underhood fuse block with a 40-amp fuse. 1. Disconnect and remove the battery. Refer to Battery Replacement in SI. 2. Remove the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 3. Disconnect the underhood fuse block from it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. It is only necessary to raise the fuse block enough to access the harness connectors. Do not remove the complete assembly from the vehicle. 4. Locate the engine wiring harness junction block assembly (X1) on the back (underside) of the underhood fuse block and disconnect it from the underhood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 5. Find pin A2, Circuit 532, cooling fan motor supply voltage. Refer to Electrical Center Identification Views, Fuse Block-Underhood X1 in SI. 6. Remove the harness back cover. Remove the TPA (terminal position assurance) clip and remove connector A2 from the junction block. Cut the terminal off and tape the wire end with electrical tape. 7. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 8. Locate the electrical connector to the right cooling fan and disconnect the wiring connector from the fan. 9. Disengage pin B, wire 3 GY, circuit 532, cooling fan motor supply voltage, from the connector housing (pull to seat terminal). Cut the terminal off of the wire and remove the wire from the connector housing. 10. Tape the end of the wire with electrical tape. 11. Prepare a 1.82 m (6 ft) section of automotive grade 5.0 mm (10 GA) wire and an equal length of 6 mm (1/4 in) flexible plastic conduit, GM P/N 12051375. 12. Run the new wire through the fan wire connector housing as shown. 13. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 14. Strip the wire insulation as required and install the terminal, GM P/N 12033997, on the wire. Secure the wire and terminal into the fan wire Page 5336 Fuse Block - Underhood X2 Page 10286 Courtesy Lamp: Service and Repair Luminescent Lamp Replacement - Roof Console Luminescent Lamp Replacement - Roof Console System Diagnosis Idle Speed: Testing and Inspection Throttle/Idle Learn Description The engine control module (ECM) learns the idle position of the throttle plate to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned. A vehicle that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero. The idle may be unstable or a DTC may set if the learned values do not match the actual airflow. Conditions for Running the Throttle Learn Procedure * DTCs P0101, P0102, P0103, P0107, P0108, P0111, P0112, P0113, P0506, and P0507 are not set. * The engine speed is between 450-4,000 RPM. * The manifold absolute pressure (MAP) is greater than 5 kPa. * The mass air flow (MAF) is greater than 2 g/s. * The ignition 1 voltage is greater than 10 volts. Throttle Learn With Scan Tool-Reset 1. Ignition ON, engine OFF. With a scan tool, perform the Idle Learn Reset in Module Setup. 2. Start the engine, monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation parameter value should equal 0 percent and the engine should be idling at a normal idle speed. ‹› If the engine is not idling normally, proceed with the Learn portion of the diagnostic. 3. Clear the DTCs and return to the diagnostic that referred you here. Without Scan Tool-Learn Important: Do NOT perform the Without Scan Tool-Learn procedure if DTCs are set. Refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle). 1. The engine speed is between 450-4,000 RPM. 2. The manifold absolute pressure (MAP) is greater than 5 kPa. 3. The mass air flow (MAF) is greater than 2 g/s. 4. The ignition 1 voltage is greater than 10 volts. 5. Start and idle the engine in Park for 3 minutes. 6. With a scan tool, monitor desired and actual RPM. 7. The ECM will start to learn the new idle cells and Desired RPM should start to decrease. 8. Ignition OFF for 60 seconds. 9. Start and idle the engine in Park for 3 minutes. Important: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. 10. After the 3 minute run time the engine should be idling normal. ‹› If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles. 11. After the drive cycle, the engine should be idling normally. ‹› If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6. 12. Once the engine speed has returned to normal, clear DTCs. Procedures Fluid Pump: Procedures Auxiliary Fluid Pump Priming 1. The transmission must be in the vehicle and partially filled with fluid (approximately 8 quarts). 2. To prime the auxiliary pump, use the Tech II and follow the listed menus in order: 1. Tech II Diagnosis 2. 2009 3. Car 4. Chevy 5. Z 6. Hybrid 7. Powertrain (F0) 8. ECM (F1) 9. Special Functions (F2) 10. Hybrid Outputs (F1) 11. Aux Trans Pump 12. Aux Trans Fluid Pump Co. 13. Aux Trans Fluid Pump Re ON/OFF 3. During the last step, hold the power ON switch for approximately 30-60 seconds. The auxiliary pump will be primed. 4. Remove Tech II tool. 5. The transmission is ready to be topped off with transmission fluid. Page 5334 Fuse Block - Underhood X1 Page 6617 Fuse Block - Rear Bottom View Page 2378 Page 10082 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 2791 Page 8817 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement Rear Side Door Bottom Auxiliary Sealing Strip Replacement Page 8198 Page 9499 Service and Repair Sound Proofing / Insulation: Service and Repair Front Fender Insulator Replacement Page 8251 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wire dress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2358 Page 4644 Transmission Speed Sensor: Connector Views Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Output Shaft Speed (OSS) Sensor (MH2 or MH8) Locations Oxygen Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Lower Front and Rear of the Engine Components (LY7) A/T Controls - Downshift Hesitation/Delayed Shifting Control Module: Customer Interest A/T Controls - Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9603 Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder Replacement Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 3388 Fuel Injector 4 (LAT or LE5 or LE9) Fuel Injector 4 (LY7) Page 6364 Inside Rearview Mirror (ISRVM) (DD7 or UE1 or 2LT) Page 7439 Note: Align the left air outlet duct to the left air outlet duct extension. 1. Install the left air outlet duct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the left air outlet duct screws and tighten to 2.5 Nm (22 lb in). 3. Connect the wire harness clip at the left air outlet duct. 4. Install the I/P assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Page 2799 Interior - Rear Shelf Foam Seal Is Loose Control Module: Customer Interest A/T Controls - Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5637 Air Temperature Actuator Air Temperature Sensor - Lower (C68) Page 9494 Page 2617 Service and Repair Power Distribution Relay: Service and Repair Relay Replacement Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 9607 Page 3623 Shift Solenoid: Specifications 6T70/6T75 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Page 7840 * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Courtesy Transporation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the actual cost of the woven polyester electrical tape required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the involved vehicle listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your facility for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Turn Signal Switch Bracket Replacement Turn Signal Switch: Service and Repair Turn Signal Switch Bracket Replacement Turn Signal Switch Bracket Replacement Page 3195 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH8) Page 5151 Page 9804 Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Page 8199 Page 5658 Blower Motor Resistor (C60) Page 4174 Shifter A/T: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Transmission Control Lever Knob Replacement Transmission Control Lever Knob Replacement Removal Procedure 1. Release the boot (2) from the shift control knob (1) by pulling the boot retainer downward. 2. Remove the shift knob retaining screw (3). 3. Remove the shift knob (1) from the shift control. Installation Procedure Service and Repair Power Distribution Relay: Service and Repair Relay Replacement Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Page 3799 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Electronic Components (MH8) Page 8426 Disclaimer Page 652 Diagrams Auxiliary Water Pump: Diagrams Component Connector End Views Heater Coolant Pump (HP7) Page 3815 Shift Solenoid: Service and Repair 6T70/6T75 - Automatic Transmission Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover Replacement). 2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3). 5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring (8) to the side. Spring will be released with the removal of the control valve body assembly. Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure Important: If replacing the steering wheel position sensor, the new sensor MUST come with a locating pin installed. If a locating pin is not installed, return and reorder a new steering wheel position sensor. Do not apply force to the steering wheel position sensor in a sideways direction. When reusing the steering wheel position sensor you must install a locating pin before removing it from the steering column. If the steering wheel position sensor loses its correct position it must be discarded. The locating pin diameter must be in the range of 1.0-2.0 mm. 1. Set the front wheels in the straight-ahead position and install anti-rotation pin J 42640 in the steering column lower access hole. 2. Disconnect the intermediate steering shaft from the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering/Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 3. Disconnect any electrical connectors as needed. 4. Remove the steering wheel position sensor. Assembly Procedure Page 4942 7. Disconnect the LR brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 8. Disconnect the RR brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Locations Pressure Regulating Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 602 1. Install the park brake warning lamp switch (2) to the park brake pedal assembly (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch screw (3) and tighten to 2 Nm (18 lb in). 3. Connect the electrical connector to the park brake warning lamp switch. 4. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 5. Check the operation of the park brake warning lamp switch. Page 2830 Page 6877 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Page 7731 Page 9297 Heated Seat Control Module - Passenger X3 (KA1) Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Switch Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the oil pressure switch. 3. Remove the engine oil pressure switch. Installation Procedure Page 10567 Turn Signal Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Page 1390 Body Control Module (BCM) X2 Page 1204 8. Remove the remaining oil pan bolts and the oil pan. 9. Remove the oil pan gasket. 10. Remove the oil level control valve. 11. Remove the oil filter and oil filter O-ring seal. The seal may stay in case when filter is removed. Page 6145 Body Control Module (BCM) Bottom View Page 10597 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Left Side Front Side Door Window Switch Replacement - Left Side Page 4321 4. Remove the PNP switch lever nut and lever. 5. Remove the PNP switch. Refer to Park/Neutral Position Switch Replacement (See: Sensors and Switches - A/T/Transmission Position Switch/Sensor/Service and Repair). 6. Remove the transmission upper side cover bolts. 7. Install the engine support fixture. Refer to Engine Support Fixture (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Support Fixture). 8. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 9. Remove the left front tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 10. Remove the left lower control arm. Refer to Lower Control Arm Replacement (See: Steering and Suspension/Suspension/Control Arm/Service and Repair/Front Suspension). 11. Remove the wheel drive shaft from the transmission. Refer to Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement). 12. Disconnect the steering rack intermediate shaft. Refer to Steering Gear Replacement (See: Steering and Suspension/Steering/Steering Gear/Service and Repair/Steering Gear Replacement). 13. Remove the frame. Refer to Frame Replacement (See: Body and Frame/Frame/Service and Repair). Communication Interface Module Replacement Communications Control Module: Service and Repair Communication Interface Module Replacement Communication Interface Module Replacement Page 6441 Turn Signal/Multifunction Switch X2 Service and Repair Air Bag(s) Arming and Disarming: Service and Repair SIR Disabling and Enabling SIR component location affects how a vehicle should be serviced. There are parts of the SIR system installed in various locations around a vehicle. To find the location of the SIR components refer to SIR Identification Views (See: Restraint Systems/Air Bag Systems/Locations). There are several reasons for disabling the SIR system, such as repairs to the SIR system or servicing a component near or attached to an SIR component. There are several ways to disable the SIR system depending on what type of service is being performed. The following information covers the proper procedures for disabling/enabling the SIR system. SIR Service Precautions Warning When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. The inflatable restraint sensing and diagnostic module (SDM) maintains a reserved energy supply. The reserved energy supply provides deployment power for the air bags if the SDM loses battery power during a collision. Deployment power is available for as much as 1 minute after disconnecting the vehicle power. Waiting 1 minute before working on the system after disabling the SIR system prevents deployment of the air bags from the reserved energy supply. General Service Instructions The following are general service instructions which must be followed in order to properly repair the vehicle and return it to its original integrity: * Do not expose air bags to temperatures above 65°C (149°F). * Verify the correct replacement part number. Do not substitute a component from a different vehicle. * Use only original GM replacement parts available from your authorized GM dealer. Do not use salvaged parts for repairs to the SIR system. Discard any of the following components if it has been dropped from a height of 92 cm (3 feet) or greater: * Inflatable restraint sensing and diagnostic module (SDM) * Any air bag * Driver steering wheel air bag coil * Any impact sensor * Seat belt anchor and/or retractor pretensioners * Passenger presence module and/or occupant sensor Disabling Procedure - Air Bag Fuse 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. Note: The SDM may have more than one fused power input. To ensure there is no unwanted SIR deployment, personal injury, or unnecessary SIR system repairs, remove all fuses supplying power to the SDM. With all SDM fuses removed and the ignition switch in the ON position, the AIR BAG warning indicator illuminates. This is normal operation, and does not indicate a SIR system malfunction. 3. Locate and remove the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Diagrams/Electrical Diagrams/Air Bag Systems) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 4. Wait 1 minute before working on the system. Campaign - Airbag Readiness Light/Service Airbag Message Technical Service Bulletin # 10085D Date: 110203 Campaign - Airbag Readiness Light/Service Airbag Message CUSTOMER SATISFACTION Bulletin No.: 10085D Date: February 03, 2011 Subject: 10085D - Airbag Readiness Light/Service Airbag Message - Replace Connectors Models: 2008 Buick Enclave 2010 Chevrolet Malibu 2008 GMC Acadia 2010 Pontiac G6 2008 Saturn OUTLOOK Supercede: The Service Procedure in this bulletin has been revised. All vehicles will not require the replacement of the front seat-mounted side impact airbag connectors.Please discard all copies of bulletin 10085C, issued November 2010. Condition Certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may experience wear which could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact air bag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG System warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG System DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Correction Dealers are to replace the front seat-mounted side impact airbag connectors. Vehicles Involved Involved are certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Part Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your Page 1126 4. Check the camber setting after tightening. 5. Adjust the camber setting if necessary. Rear Toe Adjustment Rear Toe Adjustment 1. Loosen the inner toe link cam bolt and nuts. 2. Rotate the cam bolt to the required toe specification settings. Refer to Wheel Alignment Measurement (See: Wheel Alignment Measurement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Maintain the toe setting while tightening the cam bolt nut. Tighten the rear suspension adjustment link lock nut to 110 Nm (81 lb ft). 4. Check the toe setting after tightening. 5. Adjust the toe setting if necessary. Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Page 6004 Page 5476 Fuel Pump and Sender Assembly Fuel Tank Pressure (FTP) Sensor Page 1556 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage Page 10502 - Select Fuel Composition Reset (F1). - The first parameter is "Fuel Alcohol Content" displayed as a percentage. If the Fuel Alcohol Content percentage is above 25%, this is the probable cause of DTC P0172. - From this screen the "Fuel Alcohol Content" can be reset to zero by pressing the lower right Tech 2(R) button. It will then display 0% when it's reset. Finally, reprogram the PCM with the latest calibration. This will correct for the PCM alcohol calculations. Note The PCM must be reset from this screen. It does not reset to zero when the PCM is reprogrammed. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 231 Fuse Block - Underhood X1 Page 6234 Control Solenoid Valve Assembly (MH8) Page 1238 5. Reposition the heater inlet hose clamp at the engine using the J 38185. 6. Remove the heater inlet hose from the engine. Installation Procedure 1. Install the heater inlet hose to the engine. 2. Reposition the heater inlet hose clamp at the engine using the J 38185. Page 2900 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 9683 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 10114 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 4197 4. Install the transmission range selector lever cable to the transmission control lever base. 5. Connect the transmission range selector lever cable terminal (2) to the shift lever pin. 6. Install the center floor air outlet. Refer to Rear Floor Air Duct Replacement (See: Heating and Air Conditioning/Air Duct/Service and Repair/Rear Floor Air Duct Replacement). 7. Install the transaxle shift control cable to the cable bracket. Ensure the cable retainer (1) is fully secured to the transmission bracket. 8. Connect the transaxle shift control cable terminal to the transaxle manual shift lever pin. 9. Adjust the automatic transmission range selector lever cable. Refer to Range Selector Lever Cable Adjustment (See: Adjustments/6T30/6T40/6T45 - Automatic Transmission). Page 9088 Page 9685 Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Fuel Pressure Gauge Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gauge Installation and Removal Fuel Pressure Gauge Installation and Removal Special Tools CH-48027-100 - Digital Pressure Gauge For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Connect the CH-48027-1 - gauge (1) to the CH-48027-2 - adapter (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027-100 - gauge, refer to the manufacture's directions. Removal Procedure Page 5520 Ignition Control Module (ICM) (LZ4 or LZE) Page 8065 1 - Seat Back Cover - Passenger 2 - Heated Seat Element - Passenger Back (KA1) 3 - Seat Back Cushion Pad - Passenger 4 - Seat Belt Switch - Passenger 5 - Seat Horizontal Motor - Passenger (1LZ) 6 - Seat Rear Vertical Motor - Passenger (1LZ) 7 - Heated Seat Control Module - Passenger (KA1) 8 - Seat Front Vertical Motor - Passenger (1LZ) 9 - Heated Seat Switch - Passenger (KA1) 10 - Seat Adjuster Switch - Passenger (1LZ) 11 - Inflatable Restraint Front Passenger Presence System (PPS) Module 12 - Seat Cushion - Passenger 13 - Heated Seat Element - Passenger Cushion (KA1) 14 - Seat Cover - Passenger Page 5268 Auxiliary Power Outlet: Service and Repair Accessory AC and DC Power Control Module Replacement Accessory AC and DC Power Control Module Replacement Page 6064 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 3944 Page 5698 X402 Inline Harness Connector End Views X402 Rear Lamp Harness to Right Tail Lamp Harness (without LTZ) X403 Inline Harness Connector End Views X403 Body Harness to Rear Wheel Speed Sensor Harness Locations Power Mirror Switch: Locations Door Component Views Driver Door Components 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Locations Knock Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Lower Front and Rear of the Engine Components (LY7) Low/Reverse Servo Assembly Replacement Band Apply Servo: Service and Repair Low/Reverse Servo Assembly Replacement Low/Reverse Servo Assembly Replacement Removal Procedure Warning Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. 1. Position the vehicle on a hoist and raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transaxle oil pan. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). 3. Remove the oil feed pipe-to-low/reverse servo assembly bolt. Note: Remove servo cover bolts evenly to prevent damage to servo cover. 4. Remove the low and reverse band servo cover assembly bolts. 5. Pull the oil feed pipe away from the servo cover and remove the servo assembly. Disassembly Procedure Page 7610 6. Install the lower HVAC module case. 7. Install the lower HVAC module case screws and tighten to 1.5 Nm (13 lb in). 8. Install the center floor air outlet duct. 9. Install the center floor air outlet duct screws and tighten to 1.5 Nm (13 lb in). 10. Install the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Housing Assembly HVAC/Service and Repair). Page 3935 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Transmission Fluid Cooler Hose Replacement Transmission Fluid Cooler Hose Replacement Fuse Block - Underhood Relay Box: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 2376 Page 5446 Page 5656 Battery Disconnect Switch (HP7) Blower Motor Page 614 Page 372 Page 9732 Heated Seat Control Module - Passenger X1 (KA1) Page 5705 Page 6636 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. Page 9912 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Page 3374 Fuel: Testing and Inspection Fuel Composition Diagnosis Fuel Composition Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description When an E85 compatible vehicle is built, an engine control module (ECM) or powertrain control module (PCM) replaced, or when the learned alcohol content has been reset with a scan tool, the fuel system will need to contain ASTM gasoline with 15 percent or less ethanol content. If the fuel in the fuel system needs to be drained and replaced with ASTM gasoline, the engine will need to run at operating temperature and consume at least 1 liter (0.3 gallon) of fuel before the system will recognize the correct alcohol content. Either ASTM gasoline or ASTM E85 fuel can then be used. In order that the ECM/PCM recognizes a proper next fuel fill, the amount must be 11 liters (3 gallons) or more, and the ethanol content must be between 0-85 percent. Reference Information Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * J 44175 - Fuel Composition Tester * J 44175-A - Fuel Composition Tester Circuit/System Verification 1. Observe the Fuel Composition Learn parameter using the scan tool. The Fuel Composition Learn parameter should display Inactive. Note: * The key needs to be turned OFF for at least 30 seconds after the parameter displays Inactive to properly store the ethanol learned value in the ECM/PCM memory. * The vehicle may need to be driven more than 11 km (7 mi) with the engine at operating temperature. ‹› If the Fuel Composition Learn parameter displays Active, drive the vehicle until the Fuel Composition Learn parameter displays Inactive. 2. Record the ECM/PCM estimated value of the ethanol content using a scan tool. 3. Record the actual measured percentage of ethanol content using the J 44175 - Tester or J 44175-A - Tester. The ECM/PCM estimated value should be within 15 percent of the ethanol content measured with the J 44175 - Tester. ‹› If the ECM/PCM estimated value is not within 15 percent of the ethanol content measured with the J44175 Tester continue with Circuit/System Testing. Circuit/System Testing - J44175 Ethanol Content Less Than 15 Percent 1. Use the scan tool to reset the Fuel Alcohol Content parameter to 3 percent. 2. Use the scan tool to reset the fuel trim values. Circuit/System Testing - J44175 Ethanol Content More Than 15 Percent 1. Perform a complete key cycle, key ON, engine OFF, in order to ensure that the ECM/PCM recognizes a refueling event. Note: It may be necessary to partially drain the fuel tank. 2. Key OFF, add at least 11 liters (3 gallons) of non-blended gasoline to the fuel tank. 3. Use the scan tool to reset the Fuel Alcohol Content parameter to 3 percent. Note: In order to ensure the non-blended gasoline has reached the fuel injectors, the vehicle may need to be driven more than 11 km (7 mi) with Page 7627 For vehicles repaired under warranty, use the table. Disclaimer Page 3273 14. Install the left (front) catalytic converter nuts (1) at the exhaust manifold and tighten to 45 Nm (33 lb ft). 15. Remove the exhaust manifold heat shield bolts and shield. Tighten the bolts to 10 Nm (89 lb in). Page 8667 Page 10596 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Right Side Front Side Door Window Switch Replacement - Right Side Page 4944 11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 12. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 13. Remove the 3 BPMV bracket nuts (1). 14. Lower the vehicle. 15. Remove the master cylinder nuts (1). 16. Remove the master cylinder and the EBCM/BPMV and bracket as an assembly from the vehicle. Page 6817 Alignment: Service and Repair Front Camber Adjustment Front Camber Adjustment 1. Reach around the tire, using the appropriate extension and socket. 2. Loosen both strut to knuckle nuts just enough to allow for movement. Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt First Pass .................................................................................................... ................................................................................................ 100 Nm (74 lb ft) Final Pass ............... .............................................................................................................................................................. ............................... 125 degrees Page 5351 Page 7341 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 9042 Rear Compartment Sill Trim Plate Replacement Rear Compartment Sill Trim Plate Replacement Page 7906 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the SIR circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Page 9699 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 4745 Brake Caliper: Overhaul Front Brake Caliper Overhaul Front Brake Caliper Overhaul Disassembly Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Remove the brake caliper from the vehicle. Refer to Front Brake Caliper Replacement (See: Removal and Replacement/Front Brake Caliper Replacement). Warning Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Caution: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Remove the retaining ring that secures the dust boot to the caliper housing. Page 8554 Disclaimer Locations Horn Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 2489 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 7908 Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a Customer Satisfaction Program that affects your 2010 model year Chevrolet Malibu or Pontiac G6. We have learned that your 2010 model year Chevrolet Malibu or Pontiac G6 may have a condition in which wear could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact airbag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG system warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG system DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Your Malibu or G6 may have been serviced previously to reroute and secure both front seat-mounted side impact airbag wire harnesses. However, there have been reports of the SERVICE AIR BAG message illuminating in the Driver Information Center (DIC) on vehicles that had the wire harnesses rerouted and secured, but did not have new connectors installed. Our records indicate that your vehicle may not have had the new connectors installed. What We Will Do: Since your vehicle may not have had new connectors installed, your GM dealer will inspect your vehicle to determine if new connectors have been installed, and will install two new connectors, if required. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 11034 Sunroof Sunshade Guide Replacement Sun Shade: Service and Repair Sunroof Sunshade Guide Replacement Sunroof Sunshade Guide Replacement Removal Procedure 1. Remove the sunroof sunshade panel. Refer to Sunroof Sunshade Replacement (See: Sunroof Sunshade Replacement). 2. Pulling outward, remove the sunshade guide from the sunshade panel. Installation Procedure 1. Position the guides to the sunshade panel. The spring feature should face upward. 2. Push the sunshade guides onto the sunshade panel until fully seated. 3. Install the sunshade panel. Refer to Sunroof Sunshade Replacement (See: Sunroof Sunshade Replacement). Page 3723 25 - A/Trans Fluid Pump Seal Assembly 26 - Torque Converter with Fluid Pump Housing Assembly 27 - Torque Converter and Differential Housing Bolt 28 - A/Trans Fluid Fill Tube Plug Assembly 29 - Torque Converter Assembly Component Location Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear Campaign - Airbag Readiness Light/Service Airbag Message Technical Service Bulletin # 10085D Date: 110203 Campaign - Airbag Readiness Light/Service Airbag Message CUSTOMER SATISFACTION Bulletin No.: 10085D Date: February 03, 2011 Subject: 10085D - Airbag Readiness Light/Service Airbag Message - Replace Connectors Models: 2008 Buick Enclave 2010 Chevrolet Malibu 2008 GMC Acadia 2010 Pontiac G6 2008 Saturn OUTLOOK Supercede: The Service Procedure in this bulletin has been revised. All vehicles will not require the replacement of the front seat-mounted side impact airbag connectors.Please discard all copies of bulletin 10085C, issued November 2010. Condition Certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may experience wear which could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact air bag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG System warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG System DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Correction Dealers are to replace the front seat-mounted side impact airbag connectors. Vehicles Involved Involved are certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Part Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your Page 658 2. Install the lower air temperature sensor. 3. Install the right front floor console extension panel. Refer to Front Floor Console Extension Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Extension Panel Replacement - Right Side). Body Control Module Fuse: Application and ID Body Control Module Electrical Center Identification Views Body Control Module (BCM) Label Connector End Views By Name Multiple Junction Connector: Diagrams Connector End Views By Name Ca - Do Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve (LZ4 or LZE) Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust (LY7) Page 5323 Body Control Module (BCM) X4 Page 5521 Ignition Switch Page 10055 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Starting and Charging/Power and Ground Distribution/System Diagram/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Page 2952 5. Remove the fuel injector wiring harness clips (1) from the fuel rail tabs. 6. Disconnect the fuel injector wiring harness electrical connector (2) from the number 3 fuel injector. 7. Squeeze tabs and slide the MAP sensor (1) upward. Installation Procedure Page 6073 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Page 7472 Disclaimer Page 1350 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating 2 types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance-oil-based substance - Layered appearance-silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid-dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement) * Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Front Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) * Rear Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement) Also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Fluid Reservoir/Service and Repair). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Front Brake Caliper Overhaul (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Front Brake Caliper Overhaul)or Front Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) Page 5217 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 3984 Transmission Mode Indicator - A/T: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Automatic Transmission Control Indicator Replacement Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Engine Compartment Fuse Block - Owners Manual Fuse: Locations Engine Compartment Fuse Block - Owners Manual ENGINE COMPARTMENT FUSE BLOCK The vehicle may not be equipped with all the fuses and features listed. The engine compartment fuse block is located on the driver side of the engine compartment, near the battery. Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the covers on any electrical component. Page 9204 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Page 2789 Steering - Front End Clunk/Rattle/Knock On Bumps Steering Shaft: All Technical Service Bulletins Steering - Front End Clunk/Rattle/Knock On Bumps TECHNICAL Bulletin No.: 06-02-32-007G Date: April 05, 2010 Subject: Clunk, Knock or Rattle Noise From Front of Vehicle While Driving or Turning Over Bumps at Low Speeds (Diagnose Noise and Perform Outlined Repair) Models: 2004-2006 Chevrolet Malibu Maxx 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn Aura Supercede: This bulletin is being revised to update the Parts Information for the bolt. Please discard Corporate Bulletin Number 06-02-32-007F (Section 02 - Steering). Condition 1 Some customers may comment on a clunk noise heard and felt in the steering wheel while driving at slow speeds and turning. The clunk noise may appear to be directly in front of the driver. Hitting a bump while turning can produce the clunk noise. Sometimes the noise may be duplicated when the vehicle is sitting still and the steering wheel is turned 90 degrees in either direction before initially centering the steering wheel. Cause 1 The clunk noise may be caused by a slip/stick condition between the inner and outer components of the intermediate shaft. Important Revised design intermediate shafts went into production in the 2009 model year and are the only design currently available through GMSPO since approximately September 2008. Since any model year vehicle could have had a second design shaft installed, it is critical to identify it before proceeding. The revised design intermediate shafts will NOT tolerate any type of lubricant per the following instructions. Adding lube to the second design shafts will cause a clunk noise in a very short period of time. Use the following pictures to identify which design of shaft you are servicing. Electric Assist Power Steering First Design - Bare Steel Tube (Lube OK) Service and Repair Oil Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Remove the drive belt. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 2. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement (See: Engine Oil Dip Stick - Dip Stick Tube/Service and Repair). Note: The support fixture bar must be installed to provide enough access to remove and properly tighten the oil pan bolts. 3. Install the engine support fixture. Refer to Engine Support Fixture (See: Service and Repair/Removal and Replacement/Engine Support Fixture). 4. Remove engine mount. Refer to Engine Mount Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Engine Mount/Service and Repair/Engine Mount Replacement). 5. Using the engine support fixture, raise the engine approximately 76 mm (3 in). 6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 7. Loosen the upper air conditioning (A/C) compressor bolts. 8. Remove the lower A/C compressor bolt. 9. Place a suitable drain pan under the oil pan drain plug. 10. Remove the oil pan drain plug. 11. Drain the engine oil. 12. Reinstall the oil pan drain plug until snug. Page 328 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 2695 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LAT or LE5 or LE9) Crankshaft Position (CKP) Sensor (LY7) Page 6635 "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN(s) 19118426 and 20968489 will not be eligible for RIM management. * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Service Procedure Replace Wire Harness Connector 2010 Chevrolet Malibu and 2010 Pontiac G6 Tools Required - J 38125-7 Crimp Tool - J 38125-6 Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Seat shown out-of-vehicle for illustration purposed Page 4394 Constant Velocity Joint Boot: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Outer Joint and Boot Replacement Special Tools * J 8059 Snap Ring Pliers * J 35910 Drive Axle Seal Clamp Pliers Removal Procedure 1. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the seal retaining clamp. Caution: Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. 2. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining clamp with a side cutter. Discard the retaining clamp. 3. Separate the halfshaft outboard seal from CV joint outer race (1) at large diameter. 4. Slide the seal (5) away from joint along halfshaft bar (4). 5. Wipe the grease from the face of the CV joint inner race (2). 6. Spread the ears on the race retaining ring (3) with J 8059. 7. Remove the CV joint assembly (1) from the halfshaft bar (4). 8. Remove the halfshaft outboard seal (5) from the halfshaft bar (4). 9. Discard the old outboard seal. Page 7907 Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Owner Letter Owner Letter March 2011 Locations Power Seat Switch: Locations Passenger Compartment/Roof Component Views Seat Components - Driver 1 - Seat Back Cover - Driver 2 - Heated Seat Element - Driver Back (KA1) 3 - Seat Back Cushion Pad - Driver 4 - Seat Recline Motor - Driver (1LZ) 5 - Seat Horizontal Motor - Driver (AG1 or 1LZ) 6 - Seat Rear Vertical Motor - Driver (AG1 or 1LZ) 7 - Heated Seat Control Module - Driver (KA1) 8 Seat Front Vertical Motor - Driver (AG1 or 1LZ) 9 - Seat Recline Switch - Driver (1LZ) 10 - Seat Adjuster Switch - Driver 11 - Seat Belt Switch - Driver 12 - Seat Cushion - Driver 13 - Heated Seat Element - Driver Cushion (KA1) 14 - Seat Cover - Driver Seat Components - Passenger Page 7816 * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Courtesy Transporation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the actual cost of the woven polyester electrical tape required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the involved vehicle listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your facility for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Page 5431 Electronic Brake Control Module (EBCM) (LAT) Page 6624 Fuse Block - Rear X4 Page 5442 Page 8086 Seat Belt Retractor Pretensioner - Driver Seat Belt Retractor Pretensioner - Passenger Page 3468 Page 9475 Page 10738 Page 5807 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. Page 1002 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Page 9766 1 - Brake Pedal Position (BPP) Sensor 2 - Accelerator Pedal Position (APP) Sensor 3 - Accelerator Pedal 4 - Brake Pedal Page 5776 Fuse Block - Underhood Bottom View Page 4487 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement Special Tools J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. Warning Page 6375 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 2442 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position (CKP) system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * CKP sensor replacement * Any engine repairs which disturb the crankshaft to CKP sensor relationship Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the CKP system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensor activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the CKP system variation learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicle's transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 4296 1 - Control Valve Body Cover Bolt 2 - Control Valve Body Cover Assembly 3 - Control Valve Body Cover Gasket 4 - Control Valve Body Bolt 5 - Control Valve Body Cover Hole Seal 6 - Control Solenoid Valve Heat Sink Bolt 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Control Valve Body Filter Plate Assembly 9 - Control Valve Body Bolt 10 - Control Valve Body Bolt 11 Control Valve Body Assembly 12 - Control Valve Body Spacer Plate Assembly 13 - A/Trans Fluid Level Control Valve 14 - A/Trans Fluid Level Control Valve Gasket 15 - A/Trans Output Speed Sensor Bolt 16 - A/Trans Output Speed Sensor Assembly 17 - Manual Shaft Detent Spring Bolt 18 - Manual Shaft Detent Lever Spring Assembly 19 - A/Trans Input Speed Sensor Assembly 20 A/Trans Input Speed Sensor Assembly O-Ring Seal 21 - A/Trans Input Speed Sensor Bolt 22 - Fill Cap 23 - Fill Cap Seal 24 - Torque Converter Housing Gasket Page 6535 Page 9571 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 5587 Starter Generator X2 (KY1) Page 2537 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Service and Repair Muffler: Service and Repair Exhaust Muffler Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the exhaust pipe to muffler nuts. 3. With the aid of an assistant, remove the muffler insulators from the hangers. 4. Remove the muffler assembly. 5. Replace exhaust gasket. Installation Procedure Front Suspension Coil Spring Suspension Spring ( Coil / Leaf ): Service and Repair Front Suspension Coil Spring Strut, Strut Component, or Spring Replacement Special Tools J 45400 Strut Spring Compressor Disassembly Procedure 1. Remove the strut assembly. Refer to Strut Assembly Replacement (See: Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Strut/Strut Assembly Replacement). 2. Place the strut assembly into the J 45400. 3. Adjust the compressing arms to contact the coils farthest away from the center of the spring. 4. Using the J 45400, compress the spring to remove the spring tension from the upper strut mount. Page 5243 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 5430 Electric Power Steering (EPS) Module X3 (without NVH) Page 134 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 9791 Seat Adjuster Switch - Passenger (LTZ) Rear Side Door Window Switch Replacement Power Window Switch: Service and Repair Rear Side Door Window Switch Replacement Rear Side Door Window Switch Replacement Page 8363 Digital Video Disc (DVD) Display - Driver Seat Headrest X2 (SPO Accessory) (UJ5) Page 7419 1. Install a NEW stud into the bearing/hub assembly. Add enough washers (3) in order to draw the stud into the hub. 2. Install and tighten a wheel nut (1) until the head of the wheel stud is fully seated against the back of the bearing/hub flange. 3. Remove the wheel nut (1) and the washers (3). 4. Install the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. Page 4826 7. Remove the wheel nuts retaining the brake rotor to the wheel hub. 8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10 and 11 until a firm brake pedal is obtained. This will properly seat the brake caliper piston and brake pads. Rear Brake Caliper Replacement Rear Brake Caliper Replacement Removal Procedure Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 6. Install a large C-clamp over the body of the brake caliper with the C-clamp ends against the rear of the caliper body and against the outer brake pad. Caution: When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 in) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism. 7. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. Do not exceed 1 mm (0.039 in) of caliper piston travel. 8. Remove the C-clamp from the caliper. Page 2783 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement Page 6594 Service and Repair Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor Replacement Removal Procedure Warning Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. 1. Position the vehicle on a hoist and raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector. 3. Remove the VSS electrical harness retainer from the VSS stud. 4. Remove the VSS stud. 5. Remove the output VSS from the transmission case. Note: Inspect the O-ring for damage and replace if necessary. 6. Remove the O-ring from the VSS. Installation Procedure Page 6681 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. 2008 Model Year Buick Enclave, GMC Acadia and Saturn OUTLOOK Vehicles Only Note The seat mounted side impact airbag connection to the body harness is located at the forward edge of the seat, below the plastic trim. The connectors are yellow. The body harness wires are exposed - running forward in the vehicle, down through the carpet cutout in the floor. Page 8248 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Locations Wheel Speed Sensor: Locations Wheels/Vehicle Underbody Component Views Wheel Components 1 - Wheel Speed Sensor (WSS) - Right Front 2 - Wheel Speed Sensor (WSS) - Right Rear 3 Wheel Speed Sensor (WSS) - Left Rear 4 - Wheel Speed Sensor (WSS) - Left Front Page 3359 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor (2). 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2). Installation Procedure Page 6637 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. Page 5041 Page 5517 Ignition Coil 4 (LY7) Page 8197 Page 8757 1. Install the striker (2) to the door opening. Align the striker to the alignment marks. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the screws to the striker. Tighten the screws to 20 Nm (15 lb ft). 3. Adjust door striker. Refer to Door Lock Striker Adjustment (See: Adjustments). 4. Inspect the door for proper operation. 5. Install the front or the rear trim if removed. 6. Install the body lock pillar lower trim. Refer to Body Lock Pillar Lower Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Body Lock Pillar Lower Trim Panel Replacement). 7. Install the lower center pillar trim. Page 10073 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Delphi Connectors Delphi Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Specifications Alternator: Specifications Generator Usage Page 4864 Brake Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Pressure Sensor (LAT) Page 9190 GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The Locations Daytime Running Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 7357 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Electrical - Various Electrical Systems Malfunctions Body Control Module: Customer Interest Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Service and Repair Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Page 4501 3 - Torque Converter Assembly 4 - Manual Shaft and Detent Lever Assembly 5 - 2nd Clutch 6 Reverse Clutch 7 - Coast Clutch 8 - Direct Clutch 9 - Reaction Planetary Gear Set 10 - Input Planetary Gear Set 11 - Forward Clutch 12 - Lo Roller Clutch 13 - Parking Lock Actuator Assembly 14 - Differential and Final Drive Assembly 15 - Output Stub Shaft 16 - Output Speed Sensor 17 Lo/Reverse Servo Assembly 18 - Lo/Reverse Band 19 - Oil Feed Tube Assembly 20 - Input Sprag Clutch Assembly 21 - Oil Filter Assembly 22 - 2nd Roller Clutch 23 - Oil Level Control Valve 24 Drive Link Assembly 25 - Driven Sprocket 26 - Output Shaft 27 - Channel Plate Assembly 28 Input Speed Sensor 29 - 4-3 Solenoid 30 - Drive Sprocket 31 - Control Valve Body Assembly 32 Oil Pump Assembly 33 - Auxiliary Pump Disassembled Views Disassembled Views Case and Associated Parts Page 2370 4. Disconnect the engine wiring harness electrical connectors (2) from the ECM. 5. Remove the engine wiring harness clips (3) from the ECM bracket (4). Caution: Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables or when charging the vehicles battery. 6. Gently lift the ECM retainers (1) up, disengaging the retainers from the ECM (2). 7. Tilt the ECM towards the engine and remove the ECM (2) from the bracket. Installation Procedure Page 9800 Seat Heater Switch: Service and Repair Driver or Passenger Seat Heater Switch Replacement Rear Side Door Window Replacement Rear Door Window Glass: Service and Repair Rear Side Door Window Replacement Rear Side Door Window Replacement Service and Repair Dome Lamp Bulb: Service and Repair Dome Lamp Bulb Replacement Page 6261 Page 6333 Horn Assembly Page 7522 9. Remove the compressor clutch coil from the compressor. Installation Procedure 1. Carefully clean the clutch plate bolt threads with a M6x1.0 tap. Carefully blow out debris with compressed air. 2. Install the compressor clutch coil to the compressor. Page 5374 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 3943 Fluid Cooler Inlet Hose Replacement Fluid Cooler Inlet Hose Replacement Fluid Cooler Outlet Hose Replacement Fluid Cooler Outlet Hose Replacement Page 1990 12. Remove the fixed timing chain guide bolts and guide. 13. Install a 24 mm wrench on the hex on the intake camshaft in order to hold the camshaft. 14. Remove and discard the intake camshaft actuator bolt (2). 15. Remove the intake camshaft actuator (3), and the timing chain through the top of the cylinder head. 16. Remove the crankshaft sprocket (2) and friction washers (1), if equipped. Page 3353 1. Install a NEW air filter assembly. 2. Close the air cleaner cover. 3. Engage the air cleaner cover latches (1). 4. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 5. Install the air cleaner outlet duct to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Tighten the air cleaner outlet duct clamp at the air cleaner assembly to 4 Nm (35 lb in). Page 135 Electronic Brake Control Module: Diagrams Component Connector End Views Electronic Brake Control Module (EBCM) (LAT) Locations Pressure Regulating Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 3910 Disclaimer Service and Repair Valve Cover: Service and Repair Camshaft Cover Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Remove the battery box cover, LAT only. 3. Disconnect the engine wiring harness electrical connectors (2, 3) from the intake and exhaust camshaft position actuator solenoid valves. 4. Remove the ignition coils. Refer to Ignition Coil Replacement (See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair). 5. Remove the engine harness clips (4) from the cover. 6. Reposition the engine wiring harness out of the way. Page 1458 Fuse Block - Rear Top View Page 6032 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 3254 Secondary Air Injection (AIR) Pump Solenoid Bank 1 (LZ4 with NU6, or LZE with NU1 or NU5) Page 9401 Seat Rear Vertical Motor - Driver (LTZ) Page 7928 * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Courtesy Transporation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the actual cost of the woven polyester electrical tape required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the involved vehicle listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your facility for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Page 4206 3. Connect the range selector cable (2) to the range selector cable bracket. 4. Connect the range selector cable end (1) to the range selector lever. 5. Check the range selector cable adjustment. Refer to Range Selector Lever Cable Adjustment (See: Adjustments/6T30/6T40/6T45 - Automatic Transmission). Page 2008 Timing Cover: Service and Repair Engine Front Cover Replacement Removal Procedure 1. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt Tensioner/Service and Repair). 2. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 3. Remove the engine front cover to water pump bolt. 4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the engine front cover bolts. 6. Remove the engine front cover. Procedures Fuse Block: Procedures Ground Repair Electrical Grounds Proper electrical system function relies on secure, positive, corrosion-free ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacements. In general, electrical ground connections are accomplished using one, or a combination of, three attachment methods: * Welded M6 stud and nut * Welded M6 nut and bolt * Welded M8 nut and bolt Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. Determine which attachment method is used, and carry out the appropriate repair. M6 Weld Stud Replacement 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 5. Select a replacement conductive M6 rivet stud. Refer to GM parts catalog for the correct part number and application. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new rivet stud. 16. Select a new, conductive M6 nut. Refer to GM parts catalog for the correct part number and application. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 17. Install the M6 nut and tighten to 8 Nm (71 lb in). 18. Check for proper system operation. M6 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a new, conductive self-threading M7 bolt may be used to secure the ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive, self-threading M7 bolt Page 2000 23. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot. 24. Use 24 mm open ended wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot. 25. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight. Page 9567 GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The Page 9089 Locations Trunk / Liftgate Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 4924 8. Connect the electrical connector to the park brake warning lamp switch. 9. Position the carpet back into place. 10. Install the 3 park brake pedal assembly nuts (1, 2, 3) and tighten to 25 Nm (18 lb ft). Tighten in sequence as shown. 11. Pull down to remove the cable tension set pin (1). 12. Apply the park brake pedal 4 full cycles to complete the tension set. 13. Install the left front carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Removal and Replacement/Front Side Door Opening Floor Carpet Retainer Replacement). 14. Install left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). Page 6003 Rear Suspension Rear Knuckle: Service and Repair Rear Suspension Knuckle Replacement Special Tools J 45059 Angle Meter Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the park brake cable (1) from the trailing arm. 4. Remove the rear wheel bearing/hub assembly. Refer to Rear Wheel Bearing and Hub Replacement (See: Wheel Bearing/Service and Repair/Rear Suspension). 5. Remove the lower shock absorber bolt from the knuckle. Refer to Shock Absorber Replacement (See: Suspension Strut / Shock Absorber/Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement). Page 10724 Windshield: Removal and Replacement Windshield Replacement Windshield Replacement Special Tools * BO-24402-A - Glass Sealant Remover (Cold Knife) * BO-39032 - Stationary Glass Removal Tool * Use an adhesive that is approved by GM For equivalent regional tools, refer to Special Tools (See: Windows/Tools and Equipment). Removal Procedure Note: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and the interior trim. 1. Open the hood. 2. Remove the windshield wiper arms and blades. Refer to Windshield Wiper Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and Repair). 3. Remove the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Air Inlet Grille Panel Replacement). 4. Remove the interior windshield pillar garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 5. Remove the rearview mirror. Refer to Inside Rearview Mirror Replacement (See: Body and Frame/Mirrors/Service and Repair/Inside Rearview Mirror Replacement). 6. Remove the remote control door lock receiver. Refer to Remote Control Door Lock Receiver Replacement (See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Module/Service and Repair). Warning: Refer to Defroster Outlet Warning (See: Heating and Air Conditioning/Service Precautions). 7. Cover the following parts to protect from broken glass: * Upper dash pad * Defroster outlets and A/C outlets * Seats and carpeting Warning: Refer to Glass and Sheet Metal Handling Warning (See: Body and Frame/Service Precautions/Technician Safety Information/Glass and Sheet Metal Handling Warning). Note: If the original window is being reused the window lace is not serviceable. 8. Using the appropriate tool, carefully cut around the lace (1), start in the center working from side to side of the windshield to access the urethane adhesive bead. Page 6179 Fuse Block - Rear X3 Page 2841 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Locations Alarm Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 3408 6. This step also applies to the Squeeze to release style connectors ONLY. Squeeze where indicated by the arrows on both sides of the plastic ring surrounding the quick connect fitting. 7. This step applies to the Sliding retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move, try pressing the tab in from the opposite side. the tab will only move in one direction. A/T Controls - Snapshot Data Upload Information Continuously Variable Transmission/Transaxle: Technical Service Bulletins A/T Controls Snapshot Data Upload Information INFORMATION Bulletin No.: 07-07-30-010B Date: June 19, 2009 Subject: Procedure to Take Snapshot Data with a Tech 2(R) and Upload Data to a Computer Using TIS Software Models: 2004-2010 Passenger Cars and Light Duty Truck (Including Saturn; excluding Astra models) 2004-2010 HUMMER H2, H3 2004-2009 Saab 9-7X Supercede: This bulletin is being revised to update the Sending a Snapshot to GM TAC section and add the 2010 model year. Please discard Corporate Bulletin Number 07-07-30-010A (Section 07 - Transmission/Transaxle). Important Global Diagnostic System (GDS) will take the place of the Tech 2(R) on certain vehicles when communicating and diagnosing vehicle on-board electrical systems. This new diagnostic tool platform and software will be required for use with all GM Global Architecture (Global A) vehicles beginning with the 2010 Chevrolet Camaro, followed later by the Buick Allure/LaCrosse, Chevrolet Equinox, Cadillac SRX and the GMC Terrain. These vehicles will no longer permit Tech 2(R) communication for diagnostic purposes. For further information, refer to Corporate Bulletin Number 09-00-89-019 (Introduction of New Global Diagnostic System (GDS)). This procedure is intended to show the user how to take snapshot data with a Tech 2(R) and upload it to a computer. The procedure is written for an automatic transmission data snapshot on a Saturn AURA, but is similar for all applications. This procedure is written with the assumption the user has a basic understanding of how to use a Tech 2(R) already. Capturing a Snapshot of the Vehicle Data Stream 1. Connect the Tech 2(R) to the vehicle Data Link Connector (DLC) as shown above. Use a CANdi module as required. 2. Power up the Tech 2(R) and press the ENTER key at the start-up screen. 3. From the Main Menu select F0: Diagnostics. 4. Enter all vehicle information as requested on the scan tool's display. Bolded selections are vehicle specific. - Select "2007" - Select "Passenger Car (F0)" - Select "Saturn" Locations Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Electrical - Various Electrical Concerns/False Messages Door Switch: All Technical Service Bulletins Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Page 5763 Fuse Block - Rear X4 Page 2091 3. Install the thermal bypass hose to the crossover pipe. 4. Position the thermal bypass hose clamp at the crossover pipe. 5. Install the radiator inlet hose to the crossover pipe. 6. Position the radiator inlet hose clamp at the crossover pipe. Page 9908 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Page 7073 2. Install the upper control arm on the support. 3. Install the upper control arm nuts and bolts to the support. Refer to Rear Axle Upper Control Arm Replacement (See: Control Arm/Service and Repair/Rear Suspension/Rear Axle Upper Control Arm Replacement). 4. Install the wheel speed sensor wiring harness on the upper control arms and the support. 5. Secure the rear support to a transmission jack stand. 6. Raise the support into position with the aide of an assistant. Page 4148 7. Remove the 2 control valve body bolts (4) M6 x 65. 8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95. 10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body and transmission control module (TCM) assembly (5). Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 12. Remove the control solenoid valve assembly filter plate (6). * Discard the filler plate. It is not reusable. * Inspect the pressure switch manifold seals for damage or contamination. Replace the control solenoid valve assembly as necessary. * Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage around the PCS seals. Replace the upper channel plate as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (1). Page 2838 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to auto range to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Page 2772 Engine Control Module: Service and Repair Engine Control Module Replacement Removal Procedure Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Disconnect the body wiring harness electrical connector (1) from the engine control module (ECM). Page 284 Body Control Module (BCM) X4 Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Electrical - Various Electrical Systems Malfunctions Body Control Module: All Technical Service Bulletins Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Page 9971 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Page 8101 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Passenger Door Components Page 9091 Page 3711 4. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 5. Install the shift control cable to transaxle range switch lever and verify proper operation. Locations Transmission Position Switch/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components (ME7 or MN5) 1 - Park/Neutral Position (PNP) Switch Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) Page 5414 Digital Video Disc (DVD) Control Module X3 (SPO Accessory) (UJ5) Page 3526 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor. Installation Procedure Page 230 Fuse Block - Underhood Bottom View Service and Repair Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Page 2090 13. Remove the coolant crossover pipe bolts (1-4). 14. Remove the coolant crossover pipe. Installation Procedure 1. Position the coolant crossover pipe to the cylinder heads. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the coolant crossover pipe bolts (1-4) and tighten to 50 Nm (37 lb ft). Page 3275 Catalytic Converter: Service and Repair Catalytic Converter Replacement - Right Side Catalytic Converter Replacement - Right Side Special Tools J 39194-B Heated Oxygen Sensor Wrench Removal Procedure Caution: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. Caution: The use of excessive force may damage the threads in the exhaust manifold/pipe. Note: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the HO2S. Note: The HO2S may be difficult to remove when the engine temperature is less than 48°C (120°F). 1. Remove the muffler assembly. Refer to Exhaust Muffler Replacement (See: Engine, Cooling and Exhaust/Exhaust System/Muffler/Service and Repair). 2. Remove the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement (See: Steering and Suspension/Suspension/Stabilizer Bar/Service and Repair/Rear Suspension). 3. Remove the connector position assurance (CPA) retainer (3). 4. Disconnect the lower right heated oxygen sensor (HO2S) electrical connector from the engine wiring harness electrical connector (2). Page 3994 Parking Lock Cable: Adjustments 6T70/6T75 - Automatic Transmission Park Lock Cable Adjustment 1. Place the floor shift lever in the PARK position. 2. Turn the ignition key cylinder to the LOCK position. 3. If the front floor console is in place, remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). Important: * The key must not be able to be removed from the ignition cylinder with the transmission control lever in any position other than PARK. If they key can be removed in any other position, adjustment or repair is necessary. * The shift lever must not move from park unless the key is in the ON position. If the lever can be removed from park with the key in the OFF position, adjust or repair the park lock cable. 4. While using a small screwdriver to release the adjuster lock tang, rotate the threaded cable adjuster (1) until 3 threads are showing. 5. Re-check park lock operation. If park lock does not function, fine tune the cable 1/2 turn at a time until the proper operation is achieved. Page 4476 2. Install the TFP switch assembly onto the control valve body assembly and install the bolts. Tighten the control valve body bolts to 12 Nm (9 lb ft). 3. Install the transaxle case side cover. 4. Start the engine, warm up the transaxle, and check for leaks. 5. Inspect for proper fluid level. Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 6. Reset the TAP values. Refer to Transmission Adaptive Functions See: Automatic Transmission/Transaxle/Description and Operation. Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Page 1322 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Page 705 1. Install the park brake warning lamp switch (2) to the park brake pedal assembly (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch screw (3) and tighten to 2 Nm (18 lb in). 3. Connect the electrical connector to the park brake warning lamp switch. 4. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 5. Check the operation of the park brake warning lamp switch. Page 6277 Locations Coolant Temperature Sensor/Switch (For Computer): Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Front and Right Side of the Engine Components (LY7) Page 8519 Speaker: Service and Repair Radio Rear Speaker Replacement Radio Rear Speaker Replacement Page 3173 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Lower Front and Rear of the Engine Components - Oxygen Sensors (LY7) Page 4883 Brake Hose/Line: Service and Repair Rear Brake Hose Replacement Rear Brake Hose Replacement Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Clean all dirt and foreign material from the brake hose ends and brake pipe fitting. 4. Use a flare nut wrench on the brake pipe fitting (1) and a backup wrench on the brake hose (3) as shown. 5. Remove the brake hose retainer (2). Page 2756 Engine Control Module (ECM) X1 (LZ4 or LZE) Page 612 Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front Wheel Speed Sensor (WSS) - Left Rear Page 5634 Accessory AC/DC Power Control Module X2 (KV1) Page 9910 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to auto range to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Page 9415 Seat Adjuster Switch - Passenger (LTZ) Page 4890 6. Disconnect the LR brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 7. Disconnect the rear brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Page 4747 1. Lubricate the new piston seal (4) with GM approved or equivalent brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal (4) into the caliper bore. 3. Apply a thin coat of GM approved or equivalent brake fluid from a clean, sealed brake fluid container onto the outer surface area of the caliper piston (3). 4. Install the bottom half of the caliper piston (2) into the caliper bore. 5. Install the new piston dust boot seal (1) over the caliper piston (2). 6. Compress the caliper piston (2) to the bottom of the caliper bore. 7. Fully seat the piston dust boot seal (1) into caliper counterbore. 8. Install the retaining ring that secures the dust boot to the caliper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the bleeder valve to the caliper and tighten the valve to 11 Nm (97 lb in). 10. Install the bleeder valve cap. Page 9160 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 9319 4. Remove the sunshade from the tracks. Installation Procedure 1. Install the sunshade front tab to the left corner of sunroof track. Page 844 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the engine oil pressure switch. Tighten the switch to 22 Nm (16 lb ft). 2. Connect the engine wiring harness electrical connector (2) to the oil pressure switch. 3. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). Page 9983 Cruise Control: Electrical Diagrams Cruise Control Schematics Cruise Control Page 7307 Tires: Removal and Replacement Tire Dismounting and Mounting Caution: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. Caution: Damage to either the tire bead or the wheel mounting holes can result from the use of improper wheel attachment or tire mounting procedures. It takes up to 70 seconds for all of the air to completely exhaust from a large tire. Failure to follow the proper procedures could cause the tire changer to put enough force on the tire to bend the wheel at the mounting surface. Such damage may result in vibration and/or shimmy, and under severe usage lead to wheel cracking. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Note: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel, position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Caution: Failure to position valve stem in proper position while dismounting and mounting the tire may result in the TPM sensor to become damaged. 5. Position the wheel and tire so the valve stem is at the 7 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. Page 9081 Parts Information Service parts common to all 2-Way Advanced Remote Start Systems Transmitter Battery 12493150 Disclaimer Page 2034 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 adapter (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 - adapter (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 - adapter (2). 5. Remove the hose on the CH-48027-2 - adapter (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 - gauge (1) from the CH-48027-2 - adapter (2). 3. Disconnect the CH-48027-2 - adapter (2) from the CH-48027-2 - adapter (3). 4. Disconnect the CH-48027-2 adapter (3) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Install the engine cover, if required. 7. Tighten the fuel fill cap. Page 913 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LAT or LE5 or LE9) Crankshaft Position (CKP) Sensor (LY7) Page 3970 Page 5363 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a conductive M6 rivet stud and a conductive M6 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new, conductive M6 rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new, conductive M6 rivet stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 16. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). 17. Check for proper system operation. Page 3499 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor - Bank 1 Exhaust Locations Lateral Accelerometer: Locations Passenger Compartment/Roof Component Views Roof/Headliner and Under the Center Console Components 1 - Inflatable Restraint Roof Rail Module - Right Front 2 - Inflatable Restraint Roof Rail Module Left Front 3 - Yaw and Lateral Accelerometer Sensor 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Page 10760 1. Position the level indicator seal (3) to the washer solvent container (1), pressing in until fully seated. 2. Using full strength windshield washer solvent on the seal, position the washer solvent level indicator (4) to the washer solvent container (1), pressing in until fully seated. 3. Connect the washer solvent level indicator electrical connector. 4. Install the front wheelhouse panel splash shield. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 5. Fill the washer solvent container with windshield washer solvent. Page 9543 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 5529 Inflatable Restraint Side Impact Module - Right Inflatable Restraint Side Impact Sensor (SIS) - Left Page 6315 Generator Battery Vent Fan (HP7) Ha - He Page 10139 Dimmer Switch: Service and Repair Instrument Panel Lamp Dimmer Switch Replacement Page 5025 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). 2. Ensure that the location measurement of the battery current sensor was recorded for reference during installation. 3. Squeeze the ground ends of the negative battery cable together and remove the sensor (1) from the cable. Installation Procedure Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 1. Install the battery current sensor (1) by passing the ground ends of the negative battery cable through the sensor. Page 4742 Note: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 6. Install the brake pads (2) to the brake caliper bracket. 7. Remove the support (1) and reposition the brake caliper over the brake pads and to the mounting bracket. Refer to Front Brake Caliper Replacement (See: Front Brake Caliper Replacement). Rear Brake Caliper Bracket Replacement Rear Brake Caliper Bracket Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which Page 9628 Page 459 Control Module: Diagrams Component Connector End Views Automatic Transmission Auxiliary Fluid Pump Control Module (HP7 with ME7) Transmission Control Module (TCM) (ME7) Page 6271 Page 4711 - Left rear 11. Perform the automated bleed procedure as instructed by the scan tool. 12. If the automated bleed procedure is aborted, a malfunction exists. If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) to diagnose the DTC. 13. After completion of the automated bleed procedure, press and hold the brake pedal to inspect for pedal firmness. 14. If the brake pedal feels spongy, repeat the bleed procedure completely. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 17. Lower the vehicle. 18. Adjust the brake fluid level. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 19. Road test the vehicle while confirming the brake pedal remains high and firm. Page 6269 Page 6798 Frame Angle Measurement (Express / Savana Only) ........ TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 9157 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Page 4047 Page 1947 17. Install the engine wiring harness clips (5) to the intake manifold. 18. Connect the fuel injector wiring harness electrical connector (7) to the engine wiring harness electrical connector (8). 19. Install the fuel injector wiring harness electrical connector retainer (6) to the generator starter. 20. Connect the engine wiring harness electrical connector (4) to the generator starter. 21. Connect the engine wiring harness electrical connector (2) to the generator starter. 22. Connect the engine wiring harness electrical connector (1) to the TAC. 23. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (See: Cooling System/Radiator Hose). 24. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 5447 Engine Control Module (ECM) X2 (LE5 or LE9) Description and Operation Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Camshaft Position (CMP) Actuator System The camshaft position (CMP) actuator system is an electro-hydraulic operated device used for a variety of engine performance and operational enhancements. These enhancements include lower emission output through exhaust gas dilution of the intake charge in the combustion chamber, a broader engine torque range, and improved fuel economy. The CMP actuator system accomplishes this by changing the angle or timing of the camshaft relative to the crankshaft position. The CMP actuator simply allows earlier or later intake and exhaust valve opening during the four stroke engine cycle. The CMP actuator cannot vary the duration of valve opening, or the valve lift. During engine OFF, engine idling conditions, and engine shutdown, the camshaft actuator is held in the Park position. Internal to the CMP actuator assembly is a return spring and a locking pin. During non-phasing modes of the camshaft, the return spring rotates the camshaft back to the Park position, and the locking pin retains the CMP actuator sprocket to the camshaft. CMP Actuator System Operation The camshaft position (CMP) actuator system is controlled by the engine control module (ECM). The ECM sends a signal to a CMP actuator solenoid in order to control the amount of engine oil flow to a Cam Actuator passage. The pressurized engine oil is sent to unseat the locking pin, and to the vane and rotor assembly of the CMP actuator. There are 2 different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The Cam Actuator is attached to a camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position (CKP). Engine oil pressure (EOP), viscosity, temperature and engine oil level can have an adverse affect on Cam Actuator performance. Page 6771 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. 2008 Model Year Buick Enclave, GMC Acadia and Saturn OUTLOOK Vehicles Only Note The seat mounted side impact airbag connection to the body harness is located at the forward edge of the seat, below the plastic trim. The connectors are yellow. The body harness wires are exposed - running forward in the vehicle, down through the carpet cutout in the floor. Page 7607 Evaporator Core: Service and Repair Air Conditioning Evaporator Core Replacement Removal Procedure 1. Remove the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Housing Assembly HVAC/Service and Repair). 2. Remove the center floor air outlet duct screws. 3. Remove the center floor air outlet duct. 4. Drill out the lower HVAC module case heat stakes. 5. Remove the lower HVAC module case screws. 6. Remove the lower HVAC module case. Page 4327 4. Disconnect the wire harness connectors from the following components: * Pressure control solenoid * 1-2, 2-3 shift solenoids * TFP switch assembly * TCC solenoid 5. Remove the TFP switch assembly bolts and remove the switch assembly from the control valve body. The 7 TFP switch O-rings are reusable if not damaged and should remain with the pressure switch assembly. Page 5664 Page 6232 Cellular Telephone Microphone (UE1) Center Console Flood Lamp Electrical - Various Electrical Concerns/False Messages Door Position Switch: All Technical Service Bulletins Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Page 5580 Speaker - Left Front (UQ3) Speaker - Left Front (UW5) OnStar(R) - Availability for Hearing Impaired Global Positioning System: All Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Locations Steering Angle Sensor: Locations Steering Column Disassembled View 1 - Intermediate Steering Shaft 2 - Intermediate Steering Shaft Bolt 3 - Steering Wheel Position Sensor 4 - Steering Column 5 - Tilt Lever Spring 6 - Tilt Lever Nut 7 - Tilt Lever Bearing 8 - Tilt Lever Spacer 9 - Tilt Lever Retainer 10 - Tilt Lever Retainer 11 - Tilt Lever Cam 12 - Tilt Lever Follower 13 - Tilt Lever 14 - Tilt Lever Spring 15 - Intermediate Steering Shaft Nut Instrument Panel/Center Console Component Views Behind Left Side of the Instrument Panel Components Page 2962 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Lower Front and Rear of the Engine Components - Oxygen Sensors (LY7) Page 3500 Variable Induction Control Valve: Diagrams Component Connector End Views Intake Manifold Tuning (IMT) Solenoid Valve (LY7) Page 9676 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Air Inlet Grille Panel Replacement Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Air Inlet Grille Panel Replacement Page 5923 Disclaimer Page 9933 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Page 4300 1 - Control Valve Body Cover Assembly 2 - Transmission Fluid Level Indicator Assembly 3 - Fluid Level Indicator Tube - Model Dependent 4 - Fluid Level Indicator Tube Seal - Model Dependent 5 Control Valve Body Cover Assembly Gasket 6 - Control Valve Body Cover Stud 7 - Control Valve Body Cover Bolt 8 - Control Valve Body Bolt 9 - Control Valve Body Bolt 10 - Control Valve Body Cover Wiring Connector Hole Seal 11 - Control Solenoid Valve Spring 12 - Control Valve Body Bolt 13 - Control Valve Body Bolt 14 - Control Valve Body Bolt 15 - Control Solenoid (w/Body and TCM) Valve Assembly 16 - Control Solenoid (w/Body and TCM) Filter Plate Assembly 17 - Manual Shaft Detent Assembly 18 - Control Valve Body Assembly 19 - A/Trans Output Speed Sensor Assembly 20 - A/Trans Output Speed Sensor Bolt 21 - A/Trans Case Assembly 22 - Torque Converter Housing Outer Seal 23 - Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly 24 Front Differential Drive Pinion Gear Lube Tube Page 9398 1 - Seat Back Cover - Passenger 2 - Heated Seat Element - Passenger Back (KA1) 3 - Seat Back Cushion Pad - Passenger 4 - Seat Belt Switch - Passenger 5 - Seat Horizontal Motor - Passenger (1LZ) 6 - Seat Rear Vertical Motor - Passenger (1LZ) 7 - Heated Seat Control Module - Passenger (KA1) 8 - Seat Front Vertical Motor - Passenger (1LZ) 9 - Heated Seat Switch - Passenger (KA1) 10 - Seat Adjuster Switch - Passenger (1LZ) 11 - Inflatable Restraint Front Passenger Presence System (PPS) Module 12 - Seat Cushion - Passenger 13 - Heated Seat Element - Passenger Cushion (KA1) 14 - Seat Cover - Passenger Locations Fluid Pressure Sensor/Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Diagrams Speaker: Diagrams Component Connector End Views Speaker - Left Front (UQA) Speaker - Left Front (UQ3) Speaker - Left Front (UW5) Page 5203 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 8019 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Page 8250 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Locations Turn Signal Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 3459 Specifications Exhaust Manifold: Specifications Exhaust manifold ................................................................................................................................. ......................................................... 14 Nm (10 lb ft) 4T45-E - Automatic Transmission Parking Lock Cable: Service and Repair 4T45-E - Automatic Transmission Park Lock Cable Replacement Removal Procedure 1. Disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 3. Place the transmission shift control lever in the PARK position. 4. Remove the park lock cable end (1) from the park lock lever by sliding the cable end rearward off the park lock lever pin. 5. Release the park lock cable retainer (2) from the shift control base. 6. Remove the knee bolster. Refer to Driver Knee Bolster Panel Replacement (See: Restraint Systems/Knee Diverter/Service and Repair). 7. Turn the ignition key to the RUN position. Page 7632 4. Remove the liquid line from the dash clip. 5. Remove the liquid line and suction line nut from the thermal expansion valve (TXV). 6. Remove the suction line from the TXV. 7. Remove the liquid line from the TXV. 8. Remove the TXV screws. 9. Remove the TXV. Note: Cap all A/C components immediately to prevent system contamination. 10. Remove and discard the sealing washers. Installation Procedure 1. Uncap A/C components. 2. Install new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). Page 6227 Camshaft Position (CMP) Sensor - Bank 1 Intake (LY7) Page 4001 Important: Ensure that the ignition key is in the RUN position. Do not attempt to insert the park lock cable with the key in any other position. 6. Install the cable (1) into the inhibitor housing. 7. Turn key to LOCK position. 8. Attach the park lock cable to the shift control base. Ensure the park lock cable retainer (2) is fully secured to the shift control base. 9. Install the park lock cable on the park lock lever by sliding the cable end (1) over the park lock lever pin. 10. Inspect the functional operation of the park/lock cable. Refer to Park Lock Cable Adjustment (See: Adjustments/4T45-E - Automatic Transmission). 11. Install the knee bolster. Refer to Driver Knee Bolster Panel Replacement (See: Restraint Systems/Knee Diverter/Service and Repair). 12. Install the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 13. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Page 1805 Caution: For proper tool operation, a drill motor with a 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction must be used. If the proper drill motor is not used, damage to the cylinder bore sleeve will occur. 12. Fasten the drive adapter EN 45680-886 into the drill chuck. Caution: Ensure that there are no crimps in the air feed hose or the vacuum hose. Crimps in the hose may cause metal shavings to exit the cutting tool in any direction, causing engine damage. 13. Connect a compressed air supply (75-125 psi) to the male quick connect located on EN 45680-881 trim tool assembly. Turn the compressed air valve to the open position. This starts the venturi vacuum system that will catch the metal shavings. 14. Place the EN 45680-886 drive adapter and the drill assembly vertically onto the EN 45680-881 drive adapter end of trim tool assembly. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds. 15. Remove the EN 45680-886 drive adapter (1) and the drill assembly from the EN 45680-881 trim tool assembly. 16. Turn OFF the compressed air valve. 17. Remove the EN 45680-881 trim tool assembly from the engine block. 18. Wipe the cylinder bore sleeve and the surrounding areas of any powder residue. Remove the EN 45680-883 metal shaving catch plug. Page 7798 * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Courtesy Transporation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information Submit a transaction using the table below. * The amount identified in "Net Item" should represent the actual cost of the woven polyester electrical tape required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the involved vehicle listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your facility for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Page 233 Fuse Block - Underhood X2 Page 6413 Speaker - Right Front (UW5) Speaker - Right Front Tweeter Page 7810 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 8968 8. Install the three pieces of foam to the attaching bracket starting at the top center inside the bracket and proceed down across the fuel lines, then at the inside of the bracket at the left and right positions of the center piece of foam. Finally, install the last two pieces of foam to the inside bracket at the left and right extended sides behind the retaining holes as shown above. 9. Reposition the radiator surge tank back onto the bracket and seat the two retaining tabs on the tank. 10. Drive the vehicle to verify that the noise is no longer present. Parts Information Order Adhesive Back Shim Stock from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 3844 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Front of the Transmission Components (MH2 or MH8) Page 1187 Drive Belt: Service and Repair Drive Belt Replacement Special Tools EN-48932 - Hydraulic Belt Tensioner Compressor For equivalent regional tools, refer to Special Tools (See: Engine, Cooling and Exhaust/Engine/Tools and Equipment). Removal Procedure 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Filters/Air Cleaner Housing/Service and Repair). Note: the tensioner stop is critical and must be removed prior to Compressing the drive belt tensioner spring. 2. If equipped, remove the tensioner stop fastener (1) and stop (2). 3. Install the EN-48932 compressor to the drive belt tensioner spring. 4. Compress the drive belt tensioner spring fully using the EN-48932 - compressor. Page 7097 3. Install the stabilizer shaft to knuckle bolt. Refer to Stabilizer Shaft Replacement (See: Stabilizer Bar/Service and Repair/Rear Suspension). 4. Install the toe link to knuckle bolt and nut. Refer to Rear Suspension Link Replacement - Toe Link (See: Rear Knuckle Alignment Link/Service and Repair). Page 5787 Fuse Block - Rear Top View Page 7123 Stabilizer Bushing: Service and Repair Rear Suspension Stabilizer Shaft Insulator Replacement Removal Procedure Important: The stabilizer shaft insulators and clamps can only be service when the stabilizer shaft is removed from the vehicle. Remove the rear stabilizer shaft assembly. Refer to Stabilizer Shaft Replacement (See: Service and Repair/Rear Suspension). Installation Procedure Important: The installation of the insulators, clamps and bolts and torque specifications reside in the stabilizer shaft replacement procedure. Install the rear stabilizer shaft assembly. Refer to Stabilizer Shaft Replacement (See: Service and Repair/Rear Suspension). Heated Oxygen and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Locations Central Control Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 2848 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Page 9576 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Procedures Tires: Procedures Tire Repair Tire Repair Warning * Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. * Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. * NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. * NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Note: * NEVER repair tires worn to the tread indicators 1.59 mm (2/32 in) remaining depth. * NEVER repair tires with a tread puncture larger than 6.35 mm (1/4 in). * NEVER substitute an inner tube for a permissible or non-permissible repair. * NEVER perform an outside-in tire repair (plug only, on the wheel). * Every tire must be removed from the wheel for proper inspection and repair. * Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. * Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection Page 7809 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 1381 Fuse: Locations Rear Compartment Fuse Block - Owners Manual REAR COMPARTMENT FUSE BLOCK The rear compartment fuse block is located in the trunk of the vehicle. Access the fuse block through the trunk panel on the driver side of the rear cargo area. Locations Power Door Lock Switch: Locations Door Component Views Driver Door Components 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Passenger Door Components Page 2631 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (LAT or LE5 or LY7 or LE9) Page 9527 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Page 1799 5. Align the installation arbor (1) onto the top of the cylinder bore sleeve (2). 6. Align the pusher block (2) of EN 45680-883 cylinder bore sleeve installer into the groove of EN 45680-881 fixture (1). Page 6239 Data Link Connector (DLC) Page 3707 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement Special Tools J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. Warning Page 9337 Sunroof / Moonroof Switch: Diagrams Component Connector End Views Sunroof Switch (CF5) Page 7959 "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. PN(s) 19118426 and 20968489 will not be eligible for RIM management. * To obtain the Woven Polyester Electrical Tape (PET), contact Kent Automotive at 1-888-YES-KENT (1-888-937-5368) and request the special order part number above. Service Procedure Replace Wire Harness Connector 2010 Chevrolet Malibu and 2010 Pontiac G6 Tools Required - J 38125-7 Crimp Tool - J 38125-6 Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Seat shown out-of-vehicle for illustration purposed Page 10431 Page 5605 Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve (ME7 or MN5) Page 9805 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement Page 10086 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 6870 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Page 2932 Knock Sensor: Service and Repair Knock Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (1) from the knock sensor pigtail electrical connector (6). 4. Remove the knock sensor electrical connector pigtail (6) clip from the oil level indicator tube bracket. 5. Remove the knock sensor bolt. 6. Remove the knock sensor. Installation Procedure Page 6161 Fuse Block - Underhood Top View (LZ4 or LZE) Page 8960 9. From below, push up on the clip slot mounting tab as shown and engage the clip on the front floor console accessory trim plate. Repeat this step on the opposite side. 10. Check the shifter trim plate retention. The trim plate should not lift up just using your finger tips. If the trim plate does lift up, the retaining clips are not seated. 11. Install the left and right console side extension panels. 12. Install the shift knob. Refer to Floor Shift Control Knob Replacement in SI. 13. Place the shifter into Park ("P") and turn the ignition key to the OFF position. 14. Release the parking brake. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Locations Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 6391 Recirculation Actuator (C68) Remote Control Door Lock Receiver (RCDLR) Page 3394 Fuel Injector: Testing and Inspection Fuel Injector Diagnosis Fuel Injector Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The control module enables the appropriate fuel injector pulse for each cylinder. The ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. The Active Fuel Injector Tester (AFIT), CH-47976, is used to test the fuel pump, fuel system leak down, and the fuel injectors. Following the User Guide, CH 47976-11, and the on screen prompts or selections, will indicate the steps required to perform each of the available tests. The tester will perform all of the tests automatically and display results of the test. The results can also be down loaded for storage and printing. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Special Tools CH-47976 Active Fuel Injector Tester Component Testing Fuel Injector Coil Test Verify the resistance of each fuel injector with one of the following methods: * If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of each fuel injector should be 11-14ohm. ‹› If the injectors measure OK, perform the AFIT Test Procedure. ‹› If not within the specified range, replace the fuel injector. * If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each fuel injector with a DMM. Subtract the lowest resistance value from the highest resistance value. The difference between the lowest value and the highest value should be equal to or less than 3ohm. ‹› If the difference is equal to or less than 3ohm, refer to AFIT Test Procedure. ‹› If the difference is more than 3ohm, add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance Page 1135 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) enables the fuel pump relay when the ignition switch is turned ON. The ECM will disable the fuel pump relay within 2 seconds unless the ECM detects ignition reference pulses. The ECM continues to enable the fuel pump relay as long as ignition reference pulses are detected. The ECM disables the fuel pump relay within 2 seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Powertrain Management/Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH 48027 - Digital Pressure Gauge * J 37287 - Fuel Line Shut-off Adapter * J 37287-FF - Fuel Line Shut-off Adapters, if equipped with an LE9 engine Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test, review the User Manual CH 48027-5 for Safety Information Instructions. 1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. Locations Solar Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 235 Fuse Block - Underhood X3 Locations Dimmer Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 1995 6. Install the adjustable balance shaft chain guide and bolt and tighten to 10 Nm (89 lb in). 7. Reset the timing chain tensioner by performing the following steps: 1. Rotate the tensioner plunger 90 degrees in its bore and compress the plunger. 2. Rotate the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hose in the tensioner plunger. 8. Install the balance shaft drive chain tensioner and bolts and tighten to 10 Nm (89 lb in). 9. Remove the paper clip from the balance shaft drive chain tensioner. Page 5957 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 4533 4. Remove the shift lock control solenoid. Installation Procedure 1. Route the shift lock control solenoid through the opening in the front of the control assembly. Page 1998 15. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2). 16. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot. 17. Hand tighten the new intake camshaft actuator bolt. 18. Route the timing chain around the crankshaft sprocket and line up the first matching colored link with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position. 19. Install the friction washer, if applicable. Page 3552 Knock Sensor (KS) 2 (LZ4 or LZE or LY7) Page 5641 Audio Amplifier X2 (UQA) Page 87 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 307 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 6450 Window Motor - Right Rear Page 5352 Fuse Block - Rear X4 Page 6002 Page 3833 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid Page 10611 1 - Window Switch - Left Rear 2 - Window Switch - Right Rear 3 - Door Latch - Right Rear 4 Window Motor - Right Rear 5 - Window Motor - Left Rear 6 - Door Latch - Left Rear Page 5833 Disclaimer Page 7284 Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Page 2751 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (LAT) Page 6192 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a conductive M6 rivet stud and a conductive M6 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new, conductive M6 rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the rivet stud flange until bare metal is visible. 6. Using a rivet stud installer, install the replacement conductive M6 rivet stud. 7. Ensure the new rivet stud is securely fastened, with no detectable movement. Note: The rivet stud and surrounding panel area must be properly refinished prior to the installation of the ground terminal and nut to maintain positive electrical grounding. 8. Completely wrap the threads of the rivet stud with painters tape or equivalent. 9. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 10. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 11. Remove the painters tape or equivalent from the rivet stud threads. 12. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 13. Carefully remove any corrosion from the electrical ground wire terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new conductive M6 rivet stud threads. 15. Install the ground terminal to the new, conductive M6 rivet stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 16. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). 17. Check for proper system operation. Page 4149 2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid valve spring (7) into position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Install all bolts before tightening, then tighten in specified sequence. 4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x 55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6 x 42. 8. Install the 2 control valve body bolts (4) M6 x 65 and tighten to 12 Nm (106 lb in). 9. Connect the input speed sensor electrical connector (1). 10. Connect the output speed sensor electrical connector (2). 11. Connect the shift position switch electrical connector (3). 12. Install the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/6T70/6T75 - Page 3151 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) (LAT or LE5 or LE9) Knock Sensor (KS) 1 (LZ4 or LZE or LY7) Page 993 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Page 4743 may cause damage to the brake hose and in turn may cause a brake fluid leak. 3. Remove the brake caliper (2) from the brake caliper bracket (3) and support the brake caliper (2) with heavy mechanic's wire (1), or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Rear Brake Caliper Replacement (See: Rear Brake Caliper Replacement). 4. Remove the brake pads (1) from the brake caliper bracket. 5. Remove the brake pad retainers (2) from the brake caliper bracket (3). 6. Remove the brake caliper bracket bolts (2). 7. Remove the rear brake caliper bracket. 8. Inspect the brake mounting and hardware. Refer to Rear Brake Caliper Hardware Replacement (See: Rear Brake Caliper Hardware Replacement ). 9. Inspect the brake caliper bracket. 10. Replace the brake caliper bracket if cracked or damaged. Installation Procedure Page 9636 Page 4789 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Indexing Brake Rotor Assembled Lateral Runout Correction - Indexing Special Tools * CH-39544-KIT - Complete Torque Socket Set - 10 PCS, or equivalent * CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11, 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 - Conical Brake Rotor Washers (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. Service and Repair Rear Knuckle Alignment Link: Service and Repair Rear Suspension Link Replacement - Toe Link Page 9299 Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Page 5592 Starter Motor X1 Starter Motor X2 (Starter to Battery) (LAT or LE5) Page 4322 14. On vehicles equipped with the L61 engine, remove the transmission mount. Refer to Transmission Mount Replacement - Left Side (See: Transmission Mount/Service and Repair/6T70/6T75 - Automatic Transmission/Transmission Mount Replacement - Left Side). 15. Lower the vehicle. 16. Lower the LH side of the engine with the engine support fixture to allow the transmission side cover enough room to get past the left rail. 17. Raise the vehicle. 18. Remove the 11 transmission side cover bolts (3) or Studs (4) (model dependant). Caution: Pry on the corner of the case side cover near the locating dowel pins (45), to prevent damage to the sealing surfaces. 19. Remove the transmission side cover (1). 20. Remove the two side cover gaskets (5 and 6) and the side cover to driven support thrust washer (7). They may remain with the side cover. Only replace if necessary. Installation Procedure 1. If the seals were removed, thoroughly clean and dry the side cover seal grooves and the side cover seals. 2. Install the side cover gaskets (5 and 6) into the grooves on the side cover (1). 3. Retain the seals with J 36850 or equivalent. 4. Install the side cover to drive sprocket thrust washer (7) onto the side cover. 5. Retain the thrust washer with J 36850 or equivalent. Page 2527 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor (2). 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2). Installation Procedure Page 8988 Front Floor Console Rear Cover Replacement Page 8927 Grille: Service and Repair Radiator Lower Grille Replacement Radiator Lower Grille Replacement Page 7305 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off Vehicle (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Repair Instructions/Tire and Wheel Assembly Balancing - Off Vehicle). For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) 1400 K Street, N.W., Suite 900 Washington, DC 20005-2403 Telephone: 202-682-4800 E-mail: info@rma.org Website: www.rma.org Tire Rotation Tire Rotation Rotate the tire and wheel assemblies at frequent intervals to equalize wear. Refer to Maintenance Schedule (See: Maintenance). In addition to scheduled rotation, rotate the tire and wheel assembly whenever uneven tire wear is noticed. Radial tires tend to wear faster in the shoulder area, particularly in front positions. Radial tires in non-drive locations may develop an irregular wear pattern that may increase tire noise. This makes regular rotation especially necessary. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Page 2151 3. Remove the side radiator air deflector retainer. 4. Remove the side radiator air deflector. Installation Procedure Important: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur. 1. Install the side radiator air deflector. Important: Right side shown left side is similar. 2. Install the side radiator air deflector retainer. 3. Install the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement (See: Radiator Air Lower Baffle and Deflector Replacement). 4. Install the upper front fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). Page 10037 Page 4736 5. Remove the 2 brake caliper guide pin bolts. Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 6. Remove the brake caliper from the brake caliper mounting bracket. 7. Remove the brake pads (1) from the brake caliper mounting bracket (3). 8. Remove the brake pad retainers (2) from the brake caliper mounting bracket (3). Procedures Brake Pad: Procedures Brake Pad and Rotor Burnishing Warning Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Note: Use care to avoid overheating the brakes while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops in order to properly burnish the brake pads and rotors. Page 5087 Alternator: Service and Repair Generator Replacement Generator Replacement Removal Procedure Note: Service the generator as a complete unit. 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Remove the drive belt. Refer to Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 3. Remove the generator electrical connections. 4. Remove the generator mounting nuts and bolts. 5. Remove the generator. Installation Procedure Page 6146 Body Control Module (BCM) X1 Page 5329 Fuse Block - Underhood Top View (LAT) Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement Page 1222 5. Install the suction hose and liquid line to the TXV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the suction hose and liquid line nut to the TXV and tighten the nut to 20 Nm (15 lb ft). 7. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery and Recharging). 8. Leak test the fittings using the J 39400-A. 9. Install the surge tank to the surge tank bracket. Page 8975 7. Wipe off any excessive grease on the intermediate shaft to avoid damage from drips on the carpet. 8. Install the instrument panel insulator panel - left side. 9. Verify that the noise is no longer present. Condition 2 There may be interference between the clamp and the steering gear input shaft. The clamp is beveled and if forced down on the input shaft too hard, it may cause a loose fit with the intermediate shaft to input shaft joint. Correction 2 To correct this condition, perform the following steps: 1. Remove the intermediate shaft pinch bolt at the steering gear end. 2. Install a new bolt, GM P/N 07845238, but do not tighten the bolt at this time. 3. Pry the clamp up using a pry bar to position the bolt into the upper part of the groove as shown above. This will position the clamp off the bevel. 4. While keeping the clamp in the upper position, tighten the bolt. Tighten Tighten the bolt to 49 Nm (36 lb ft). 5. Verify that the clunk noise is no longer present. Condition 3 Important This condition ONLY applies to 2004-2007 Chevrolet Malibu/Maxx and 2005-2007 Pontiac G6. Some customers may comment on a knocking or rattling type noise from the front of the vehicle when driven at low speeds and over bumps. The noise only occurs when the steering wheel is in the straight ahead position and sounds like the noise is in the left suspension of the vehicle or directly in front of the driver. Correction 3 1. Ensure the noise is not caused by Condition # 1. 2. Determine the source of the noise. Install the chassis ears at the following locations: - sway bar link - one side at a time - upper strut mount - one side at a time - steering gear near the pinion area - base of the steering column housing - radiator surge tank 3. If the noise is coming from the upper strut mount or sway bar link, replace as necessary and retest. 4. For 2004-2006 Chevrolet and Pontiac model year vehicles, the noise may be coming from the radiator surge tank area. (The 2007 model year vehicles use a different style radiator surge tank - refer to Step 9.) 5. If the noise is coming from the radiator surge tank, release the two retaining tabs holding the radiator surge tank and reposition the tank away from the attaching bracket and isolate with closed cell foam. 6. Cut three pieces of closed cell foam, P/N P46515 (or equivalent), into 25 mm (1 in) by 102 mm (4 in) pieces. 7. Cut two pieces of closed cell foam into 25 mm (1 in) by 6 mm (1/4 in) pieces. Page 2835 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Page 6180 Page 4368 Constant Velocity Joint: Testing and Inspection Wheel Drive Shaft Inner Joint Inspection Wheel Drive Shaft Inner Joint Inspection Inspection Procedure 1. Remove the wheel drive boot clamp (2) from the tripod housing (3). 2. Remove the wheel drive shaft tripod housing (3) from the wheel drive shaft. 3. Remove the wheel drive shaft tripod joint boot bushing (1). 4. Using a suitable cleaner, remove the excess grease from the tripod assembly. 5. Inspect the following items for damage or excessive wear: * The wheel drive shaft tripod boot * The wheel drive shaft tripod assembly * The wheel drive shaft tripod joint housing * The wheel drive shaft tripod joint bushing * The wheel drive shaft 6. If any of the internal parts are found to be excessively worn or damaged, replace the wheel drive shaft inner joint and boot. Refer to Wheel Drive Shaft Inner Joint and Boot Replacement (See: Service and Repair/Wheel Drive Shaft Inner Joint and Boot Replacement). Service and Repair Wiring Harness: Service and Repair Wiring Harness Replacement Removal Procedure Tools Required J 41101 Transaxle Connector Remover 1. Remove the transmission. 2. Remove the transmission side cover. 3. Remove the control valve body. 4. Push the J 41101 onto the pass-through connector from the outside of the transmission case in order to compress the pass-through connector's retaining tabs. 5. With the retaining tabs compressed, use a screwdriver in order to remove the pass-through connector through the inside of the transmission case. 6. Remove the wiring harness (11). Installation Procedure 1. Connect the wiring harness assembly to the following components: * The TFP switch assembly (13) * The pressure control solenoid (312) (red connector) Important: The 1-2 shift solenoids wires are red and light green. The 2-3 shift solenoid wires are red and yellow. * The 1-2 shift solenoid (305) (white connector) Page 7501 Blower Motor Resistor: Diagrams Component Connector End Views Blower Motor Resistor (C60) Page 6592 Fuse Block - Rear X4 Page 6041 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Locations Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Page 5555 Pressure Control (PC) Solenoid Valve (MN5) Locations Crankshaft Position Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 7167 8. Install the three pieces of foam to the attaching bracket starting at the top center inside the bracket and proceed down across the fuel lines, then at the inside of the bracket at the left and right positions of the center piece of foam. Finally, install the last two pieces of foam to the inside bracket at the left and right extended sides behind the retaining holes as shown above. 9. Reposition the radiator surge tank back onto the bracket and seat the two retaining tabs on the tank. 10. Drive the vehicle to verify that the noise is no longer present. Parts Information Order Adhesive Back Shim Stock from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5185 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Page 6025 6. Release the rear lower half of the wire dress cover. 7. Release the tabs that are holding the wire dress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Specifications Spark Plug: Specifications Ignition System Specifications Page 7052 4. Release and remove the steering wheel shroud (1). Installation Procedure 1. Install and secure the steering wheel shroud (1) to the steering wheel. 2. Clip the steering wheel switch bezels (1) in place. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the steering wheel switch bezel bolts (2) and tighten to 2 Nm (18 lb in). 4. Install steering wheel. refer to Steering Wheel Replacement (See: Steering Column/Service and Repair/Steering Wheel Replacement) Page 5416 Digital Video Disc (DVD) Control Module X5 (SPO Accessory) (UJ5) Page 9612 Page 4526 Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (MN5) Page 8013 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 5624 Window Switch - Passenger Page 10582 Page 2616 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 8600 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 2215 14. Install the left (front) catalytic converter nuts (1) at the exhaust manifold and tighten to 45 Nm (33 lb ft). 15. Remove the exhaust manifold heat shield bolts and shield. Tighten the bolts to 10 Nm (89 lb in). Page 1453 Page 9403 Seat Vertical Motor - Driver (without LTZ and AG1) Page 4817 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating 2 types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance-oil-based substance - Layered appearance-silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid-dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and Replacement) * Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Front Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) * Rear Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and Replacement) Also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Brake Fluid Reservoir/Service and Repair). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Front Brake Caliper Overhaul (See: Brake Caliper/Service and Repair/Overhaul/Front Brake Caliper Overhaul)or Front Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) * Rear Brake Caliper Overhaul (See: Brake Caliper/Service and Repair/Overhaul/Rear Brake Caliper Overhaul)or Rear Brake Caliper Replacement (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement) * Brake Pressure Modulator Valve Replacement (See: Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm which may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system; begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct Page 9537 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 9418 Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster and Recliner Switch Replacement Driver or Passenger Seat Adjuster and Recliner Switch Replacement Interior - Instrument Panel Top Cover Appears Warped Air Register: All Technical Service Bulletins Interior - Instrument Panel Top Cover Appears Warped TECHNICAL Bulletin No.: 08-08-49-004A Date: July 15, 2009 Subject: IP Upper Trim Panel Top Cover Appears Warped (Seat Retaining Clips) Models: 2008-2010 Chevrolet Malibu Supercede: This bulletin is being revised to add model years and to update the labor operation description. Please discard Corporate Bulletin Number 08-08-49-004 (Section 08 - Body and Accessories). Condition Some customers may comment that the instrument panel (IP) upper trim top cover "defroster grille" appears warped. Cause The retaining clips may not be properly seated, causing the clips to push the IP upper trim panel up. Correction Remove the IP upper trim panel and seat the retaining clips using the steps below. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. 2. Remove the windshield pillar garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement in SI. 3. Remove the IP upper trim panel. Refer to IP Upper Trim Panel Replacement in SI. 4. Inspect the slot of the retaining clip that was not properly seated for any flashings or obstructions. - Clean the retaining clip slot. - Make sure the anti-squeak tape is still in position on the carrier after inspection. Tip A sharp rap with your hand at each retainer location may help seat the retaining clips. 5. Install the IP upper trim panel starting with the clip that was not properly retained first. Ensure the clip is fully seated. 6. Finish installing the remaining IP upper trim panel clips making sure all the retaining clips are fully seated. Important If the IP upper trim panel was raised at the end, make sure that the end clip is still seated. The garnish molding installation may cause the end clip to release if the clip was not fully engaged into the slot. DO NOT pinch the speaker electrical wires. 7. Install the windshield pillar garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement in SI. 8. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. Warranty Information For vehicles repaired under warranty, use the table above. Page 4086 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). 6. Remove the alignment tool. Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 7. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Page 9585 Seat Fan: Electrical Diagrams Heated/Cooled Seat Schematics Driver Seat Passenger Seat Symptoms - Power Outlets Auxiliary Power Outlet: Testing and Inspection Symptoms - Power Outlets Symptoms - Power Outlets Visual/Physical Inspection * Inspect for aftermarket devices which can affect the operation of the power outlets. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories) * Inspect the accessible system components or the visible system components for obvious damage or for obvious conditions which can cause the symptom. Intermittent Electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) Symptom List Refer to Power Outlet Receptacle Malfunction (See: Power Outlet Receptacle Malfunction) in order to diagnose the system. Page 7540 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the condenser mounting bolts and tighten to 6 Nm (53 lb in). 9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields. Page 9217 Page 4165 9. From below, push up on the clip slot mounting tab as shown and engage the clip on the front floor console accessory trim plate. Repeat this step on the opposite side. 10. Check the shifter trim plate retention. The trim plate should not lift up just using your finger tips. If the trim plate does lift up, the retaining clips are not seated. 11. Install the left and right console side extension panels. 12. Install the shift knob. Refer to Floor Shift Control Knob Replacement in SI. 13. Place the shifter into Park ("P") and turn the ignition key to the OFF position. 14. Release the parking brake. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5401 Camshaft Position (CMP) Sensor - Exhaust (LAT or LE5 or LE9) Page 9664 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Delphi Connectors Delphi Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Page 2345 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 1876 8. Loosen the transaxle mount bolts (1). 9. Loosen the engine mount to bracket bolts (1). 10. Reposition both floor jacks in order to allow a 1/8 inch gap between the mount and bracket. Page 6081 Page 4694 Traction Control Switch: Diagrams Component Connector End Views Traction Control Switch (TCS) Page 1005 and Repair). 8. Lower the vehicle. 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Testing and Inspection). Locations Blower Motor Resistor: Locations Instrument Panel/Center Console Component Views Under the Right Side of the Instrument Panel Components 1 - Blower Motor 2 - Blower Motor Control Module (C68) 3 - Blower Motor Resistor (C60) Page 4639 25 - A/Trans Fluid Pump Seal Assembly 26 - Torque Converter with Fluid Pump Housing Assembly 27 - Torque Converter and Differential Housing Bolt 28 - A/Trans Fluid Fill Tube Plug Assembly 29 - Torque Converter Assembly Component Location Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear Page 2235 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement Exhaust Manifold Replacement Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (See: Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement). 2. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement Sensor 1 (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor Replacement Sensor 1). 3. If equipped with a LE5, remove the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement). 4. If equipped with a LAT, remove the catalytic converter. Refer to Catalytic Converter Replacement (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement). 5. Lower the vehicle. 6. Remove the upper exhaust manifold brace bolt (1). Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 9501 Page 3274 16. Connect the engine wiring harness electrical connector (4) to the HO2S electrical connector (3). 17. Install the CPA retainer (5). 18. Install the HO2S electrical connector rosebud clip to the oil level indicator tube tab. 19. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair). Page 2256 Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement Exhaust Manifold Heat Shield Replacement Exhaust Manifold Lower Heat Shield Replacement Exhaust Manifold Lower Heat Shield Replacement Removal Procedure Page 5505 Horn Switch Page 2829 Page 444 * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information This product is current available from Kent Industries (1-888-YES-KENT). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1788 4. Remove the connecting rod nuts and the connecting rod cap. Discard the bolts and nuts. 5. Remove the connecting rod and the piston out of the top of the engine block using the EN-43966-1 - guides. 6. Clean the cylinder bores with hot water and detergent or with a light honing. 7. Swab the bores with the engine oil and a clean, dry cloth. Installation Procedure 1. Coat the following parts with engine oil: * The piston * The piston rings * The cylinder bore * The bearing surfaces Page 9627 Locations Power Distribution Module: Locations Luggage Compartment/Rear of Vehicle Component Views Rear Window Shelf Components 1 - Cellular (UE1) and Digital Radio Antenna (U2K) 2 - Radio Antenna Module 3 - Remote Start Antenna (AP3) 4 - Speaker - Right Rear 5 - Accessory AC/DC Power Control Module (KV1) 6 Audio Amplifier (UQ3) 7 - Rear Compartment Courtesy Lamp 8 - Remote Control Door Lock Receiver (RCDLR) 9 - Digital Radio Receiver (U2K) 10 - Speaker - Left Rear Diagrams Radio Receiver: Diagrams Component Connector End Views Digital Radio Receiver (U2K) Page 2002 28. Install the upper timing chain guide and bolts. Tighten the upper timing chain guide bolts to 10 Nm (89 lb in). 29. Reset the timing chain tensioner by performing the following steps: 1. Remove the snap ring. 2. Remove the piston assembly from the body of the timing chain tensioner. 3. Install the EN-45027-2 - tool (2) into a vise. 4. Install the notch end of the piston assembly into the EN-45027-2 - tool (2). 5. Using the EN-45027-1 - tool (1), turn the ratchet cylinder into the piston. 6. Reinstall the piston assembly into the body of the tensioner. 7. Install the snap ring. Service and Repair Brake Fluid Reservoir: Service and Repair Master Cylinder Reservoir Replacement Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Removal Procedure 1. Remove the master cylinder from the vehicle. Refer to Master Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and Replacement). 2. Remove the fluid level sensor. Refer to Brake Fluid Level Indicator Switch Replacement (See: Brake Fluid Level Sensor/Switch/Service and Repair). 3. Drain the brake fluid from the master cylinder reservoir. 4. Secure the mounting flange of the brake master cylinder in a bench vise so the rear of the primary piston is accessible. 5. Carefully tap out the reservoir retaining pins until clear of reservoir. 6. Remove the reservoir from the master cylinder. 7. Remove the seals from the master cylinder reservoir. Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Page 2920 Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was disconnected. 3. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to voltage. 4. Ignition ON, test for greater than 4.5 V between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are greater than 4.5 V. ‹› If all serial data circuits are less than the specified range, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to voltage on the serial data circuit between 2 control modules * A short to voltage on the serial data circuit between a control module and a terminating resistor. Testing the Serial Data Circuits for a Short to Ground 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module. 2. Ignition OFF for 60 seconds, test for less than 1k ohm between each serial data circuit at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If all serial data circuits are greater than the specified range, replace the control module that was disconnected. 3. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuit shorted to ground. 4. Ignition OFF for 60 seconds, test for less than 1k ohm between the serial data circuits at the control module connector that was just disconnected and ground. Verify that one or more serial data circuits are less than 1k ohm. ‹› If greater than the specified range for all serial data circuits, replace the control module that was just disconnected. 5. Repeat step 3 until one of the follow conditions are isolated: * A short to ground on the serial data circuit between 2 control modules * A short to ground on the serial data circuit between a control module and a terminating resistor Testing the Serial Data Circuits for a Short between the Circuits 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is greater than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. 4. Disconnect the harness connectors with the high speed GMLAN serial data circuits at another control module, in the direction of the circuits shorted together. 5. Ignition OFF for 60 seconds, test for less than 35 ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are less than 35 ohm. ‹› If each pair of serial data circuits is within the specified range, replace the control module that was just disconnected. 6. Repeat step 3 until one of the following conditions are isolated: * Serial data circuits shorted together between 2 control modules * Serial data circuits shorted together between a control module and a terminating resistor * A shorted terminating resistor Testing the Serial Data Circuits for an Open/High Resistance 1. Ignition OFF, disconnect the harness connectors with the high speed GMLAN serial data circuits at an easily accessible control module that is not communicating. 2. Ignition OFF for 60 seconds, test for greater than 100k ohm between each pair of serial data circuits at the control module connector that was just disconnected. Verify that one pair of serial data circuits are greater than 100k ohm. ‹› If each pair of serial data circuits is less than the specified range, replace the control module that was disconnected. 3. Connect the harness connectors at the control module that was disconnected. Page 136 Electronic Brake Control Module (EBCM) (LY7 or LZ4 or LZE) Page 5362 threads. 5. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 6. Install the electrical ground terminal to the new, conductive M7 bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the M7 bolt and tighten to 9 Nm (80 lb in). 8. Check for proper system operation. M6 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a conductive M6 bolt and a conductive M6 nut may be used to secure the electrical ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 ) clearance behind the panel surface and 20 mm (0.79 ) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M6 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M6 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). Note: The repair area must be properly refinished to maintain positive electrical grounding. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a conductive M8 bolt and a conductive M8 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent to M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M8 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M8 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M8 nut and tighten to 22 Nm (16 lb ft). Note: The repair area must be properly refinished to maintain positive electrical grounding. Page 2149 2. Push upward on the radiator and downward on the condenser to snap the condenser mounting tabs into the radiator clips. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install new condenser mounting nut to the radiator and tighten to 6 Nm (53 lb in). 4. Install new condenser mounting bolts and tighten to 6 Nm (53 lb in). 5. Install the cooling fan and shroud assembly. Refer to Cooling Fan and Shroud Replacement (See: Radiator Cooling Fan/Service and Repair). Radiator Support Replacement Radiator Support Replacement Page 8205 Page 737 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 547 Power Seat Switch: Diagrams Component Connector End Views Seat Adjuster Switch - Driver (LTZ) Seat Adjuster Switch - Driver (AG1) Page 951 Seat Occupant Sensor: Locations Passenger Compartment/Roof Component Views Seat Components - Passenger 1 - Seat Back Cover - Passenger 2 - Heated Seat Element - Passenger Back (KA1) 3 - Seat Back Cushion Pad - Passenger 4 - Seat Belt Switch - Passenger 5 - Seat Horizontal Motor - Passenger (1LZ) 6 - Seat Rear Vertical Motor - Passenger (1LZ) 7 - Heated Seat Control Module - Passenger (KA1) 8 - Seat Front Vertical Motor - Passenger (1LZ) 9 - Heated Seat Switch - Passenger (KA1) 10 - Seat Adjuster Switch - Passenger (1LZ) 11 - Inflatable Restraint Front Passenger Presence System (PPS) Module 12 - Seat Cushion - Passenger 13 - Heated Seat Element - Passenger Cushion (KA1) 14 - Seat Cover - Passenger Page 8223 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Page 4527 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/4T45-E - Automatic Transmission/Control Valve Body Cover Replacement) 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/4T45-E - Automatic Transmission/Control Valve Body Cover Replacement). Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Automatic Transmission/Transaxle/Description and Operation/4T45-E Automatic Transmission/Transmission Adaptive Functions). Page 10243 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Locations Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Fuel Tank Components 1 - Evaporative Emission (EVAP) Canister 2 - Evaporative Emission (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly 4 - Fuel Tank Pressure (FTP) Sensor 5 - Fuel Tank Tires - Possible Wheel/Tire Vibration Tires: Technical Service Bulletins Tires - Possible Wheel/Tire Vibration ENGINEERING INFORMATION Bulletin No.: 09-03-10-009 Date: June 12, 2009 Subject: EI09137 - Possible Wheel/Tire Vibration on Vehicles Equipped with P225/50R18 Goodyear Tires (Engineering Information) Models: 2008-2010 Chevrolet Malibu 2008-2010 Pontiac G6 2008-2009 Saturn AURA Attention: Proceed with this bulletin ONLY if the customer has commented about this concern AND the EI number is listed in GMVIS. If the customer has not commented about this condition, or if the EI does not show in GMVIS, disregard this bulletin and proceed with diagnostics found in published service information. THIS IS NOT A RECALL. Refer to GM Corporate Service Bulletin 04-00-89-053B for more details on the use of Engineering Information bulletins. Condition Important Only vehicles equipped with 18" Goodyear Eagle LS2 P225/50R18 tires (TPC SPEC 1257 MS) are the subject of this bulletin. Some customers may comment on a tire or vehicle vibration. Cause GM Engineering is attempting to determine the root cause for a concern with vibrations in the vehicles identified above and equipped with Goodyear tires. GM has a need to obtain technical information from the dealer technician during diagnosis and PRIOR to repair. As a result, this information will be used by engineering to help root cause the customer's concern. Important If the customer vehicle has less than 800 km (500 mi) since delivery, the vibration may be caused by flat spots on the tires. While a vehicle sits in dealer inventory for extended periods, flat spots may develop on the tires that require extended driving to be eliminated. In many cases, the vibration will correct itself as the tire regains it's original round shape. Correction During diagnosis of the customer's concern, document the following information. 1. What is the customer's concern? Be specific. 2. When did the customer first notice the concern? 3. Under what conditions can the concern be duplicated? 4. Does the vehicle currently exhibit the condition? - If YES, go to Step 5 - If NO, no further repairs are possible at this time; do not proceed with this bulletin. 5. Complete the applicable sections of the Vibration Analysis Worksheet. Refer to Corporate Bulletin Number 03-00-91-001E. 6. Contact the engineer listed below and provide the data collected. Notice Following the recommendations in this bulletin does not override the GM guidelines for wheel balancing and alignments as described in Corporate Bulletin Number 01-03-10-012D. Contact Information For information and further instructions, please contact a GM engineer. Service and Repair Refrigerant Filter: Service and Repair Air Conditioning (AC) Refrigerant Filter Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 2. Remove the surge tank from the surge tank bracket. 3. Remove the suction hose and liquid line nut from the thermal expansion valve (TXV). 4. Remove the suction hose and liquid line from the TXV. 5. Remove the line clip from the dash. Page 580 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement Warning: Refer to Brake Fluid Irritant Warning (See: Brakes and Traction Control/Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Brakes and Traction Control/Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Removal Procedure 1. Remove the brake master cylinder mounting nuts from the booster and position the master cylinder to gain access to the brake fluid level sensor but do not disconnect the brake lines. Refer to Master Cylinder Replacement (See: Brakes and Traction Control/Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement). 2. Disconnect the electrical connector from the brake fluid level sensor. Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass airflow (MAF)/intake air temperature (IAT) sensor. 2. Loosen the air cleaner outlet duct clamp at the air cleaner assembly. 3. Remove the air cleaner outlet duct from the air cleaner assembly. 4. Disengage the air cleaner cover latches (1). 5. Open the air cleaner cover. 6. Remove and discard the air filter assembly. Installation Procedure Page 5744 Fuse Block - Underhood Bottom View Page 10091 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors Tyco/AMP Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 7455 6. Remove the left rear floor duct. Installation Procedure 1. Install the left rear floor duct. 2. Install the floor carpet. Refer to Front Floor Panel Carpet Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Removal and Replacement/Front Floor Panel Carpet Replacement). 3. Install the left center pillar lower garnish molding. Refer to Center Pillar Lower Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Garnish Molding Replacement). 4. Install the left front carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Removal and Replacement/Front Side Door Opening Floor Carpet Retainer Replacement). 5. Install the left front seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Replacement - Bucket). 6. Install the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). Floor Rear Air Outlet Duct Replacement - Right Side Page 2968 Heated Oxygen Sensor (HO2S) 2 (LAT or LE5 or LE9) Page 3927 2. Coat the new filter O-ring seal with a small amount of petroleum jelly, and install the filter into the case. Caution: Push straight down on the center of the oil level control valve in order to prevent damage to the case bore. 3. Install the oil level control valve. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the oil pan gasket, the oil pan, and hand start the oil pan bolts. Tighten the oil pan bolts to 12 Nm (9 lb ft). 5. Lower the vehicle. 6. Refill transaxle using DEXRON(R) VI to the specified refill capacity. * The bottom pan removal capacity is approximately 6.5 L (6.9 qt). * The complete overhaul capacity is approximately 9 L (9.5 qt). * The dry capacity is approximately 12.2 L (12.9 qt). 7. Start the engine. Warm up the transaxle and check for leaks. 8. Check for proper fluid level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Symptom Related Diagnostic Page 3942 Important: Do not manually depress the retaining clip when installing the plastic cap. 10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. 13. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. 14. A hidden yellow identification band indicates proper joint seating. 15. Fill the transmission to the proper level with DEXRON(R) VI transmission fluid. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Component Tests and General Diagnostics/6T70/6T75 - Automatic Transmission/Transmission Fluid Level and Condition Check). Page 5974 Page 9510 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Page 4712 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Hydraulic Brake System Bleeding Special Tools * J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent * J-35589-A - Master Cylinder Bleeder Adapter For equivalent regional tools, refer to Special Tools (See: Hydraulic System/Tools and Equipment). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (See: Maintenance) If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Master Cylinder Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent. Add GM approved brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent, to the J-35589-A - Master Cylinder Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent,, air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left front hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve Page 9229 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the mirror motor attaching screws and tighten to 3 Nm (27 lb in). 3. Install the mirror face. Refer to Outside Rearview Mirror Glass Replacement (See: Service and Repair/Outside Rearview Mirror Glass Replacement). Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement Page 4081 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH8) Page 6182 Page 4276 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement Special Tools J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. Warning Page 4922 11. Remove the 2 nuts from the front brake cable mounting bracket. 12. Remove the park brake pedal assembly from the vehicle. Installation Procedure 1. Install the park brake pedal assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 2 nuts to the front park brake cable mounting bracket and tighten to 10 Nm (89 lb in). Page 10224 1. Install the park brake warning lamp switch (2) to the park brake pedal assembly (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch screw (3) and tighten to 2 Nm (18 lb in). 3. Connect the electrical connector to the park brake warning lamp switch. 4. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 5. Check the operation of the park brake warning lamp switch. Intake Camshaft and Valve Lifter Replacement Camshaft: Service and Repair Intake Camshaft and Valve Lifter Replacement Intake Camshaft and Valve Lifter Replacement Removal Procedure 1. Remove the intake camshaft position actuator. Refer to Camshaft Position Intake Actuator Replacement (See: Camshaft Position Intake Actuator Replacement). Note: Remove each bolt on each cap one turn at a time until there is no spring tension pushing on the camshaft. 2. Mark the bearing caps to ensure they are installed in the original position. 3. Remove the bearing cap bolts. 4. Remove the bearing caps. Page 3249 1. Connect the secondary air injection pump hose (1) to the secondary air injection check valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) 2. Install the secondary air injection pump hose to the vehicle. 3. Connect the secondary air injection pump hose (1) to the secondary air injection pump. Refer to Plastic Collar Quick Connect Fitting Service ( See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service) Page 6293 Evaporative Emission (EVAP) Canister Purge Solenoid Valve (LY7) Evaporative Emission (EVAP) Canister Purge Solenoid Valve (LZ4 or LZE) Fuse Block - Underhood Relay Box: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 7186 1. Install the wheel bearing/hub assembly to the knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 4 wheel bearing/hub assembly nuts. Tighten the nuts to 63 Nm (47 lb ft). 3. Install the stabilizer link bolt at the knuckle. Refer to Stabilizer Shaft Replacement (See: Stabilizer Bar/Service and Repair/Rear Suspension). 4. Connect the electrical connector to the wheel speed sensor. 5. Install the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 7. Lower the vehicle. Page 6692 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 9818 Splash Guard: Service and Repair Engine Splash Shield Replacement - Right Side Engine Splash Shield Replacement - Right Side Page 8236 The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors) * Delphi Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors) * FCI Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors) * Yazaki Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy Page 6524 X318 Inline Harness Connector End Views X318 DVD Signal Cable 3B to DVD Signal Cable 2B (SPO Accessory) (UJ5) Page 5856 Ensure that the appropriate wire colors match up (as noted in Step 4) when the connection is made between the seat airbag harness and body harness. 10. Slide all four terminals (2) into the appropriate connector body as shown above. Install the blue terminal position assurance (TPA) devices onto the connector ends. 11. Add NyoGel 760 Lubricant (dielectric lubricant), P/N 12377900 (in Canada, use P/N 10953529) (Saturn retailers, use P/N 12345579) to the terminals on both sides of the connections. 12. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the body harness up to the back of the connector. 13. Reinstall the conduit on the seat airbag harness. 14. Repeat the above procedure on the passenger seat. Reinstall Seats 1. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 2. Reconnect the seat to body harness connector and the seat airbag connector. Reroute Harness and Secure Connector Follow the procedure below to re-route and attach the harness connector to the body harness bundle: 1. The original seat airbag connector was attached with a clip to the bottom of the seat (2) as shown above. 2. Using two wire ties, secure the seat airbag connector to the seat wire bundle as shown. Ensure that there is enough slack for full range of motion of the seat. 3. Inspect the wires through the full range of motion of the seat again as in Step 2. Ensure that the wires have been secured in an orientation that allows full seat motion with adequate clearance to the connectors and sufficient slack in the wires. 4. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 5. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Page 2152 Radiator Support Bracket Replacement Radiator Support Bracket Replacement Radiator Air Lower Baffle and Deflector Replacement Radiator Air Lower Baffle and Deflector Replacement Removal Procedure Page 5228 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors Yazaki Connectors Special Tools J-38125 Terminal Repair Kit Page 2976 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 2 Heated Oxygen Sensor Replacement - Sensor 2 Page 874 Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 4. Remove the transaxle range switch lever nut and lever. 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. Page 9953 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Locations Combination Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 6044 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 10057 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Page 8652 Disclaimer Page 8104 Inflatable Restraint Side Impact Sensor (SIS) - Right Page 7426 Recirculation Actuator (C60) Recirculation Actuator (C68) Page 5052 3. Reset the radio stations and the clock. 4. Re-initialize the power windows. Refer to Power Window Reinitialization (See: Windows and Glass/Windows/Service and Repair/Procedures). Page 6265 Page 4877 23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. 24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 25. Insert the finishing cone into the forming ram. 26. Rotate the hydraulic fluid control valve clockwise to the closed position. 27. Rotate the body of the J 45405 until it bottoms against the die cage. 28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the finishing cone bottoms against the dies. 29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract. 30. Loosen the die clamping screw and remove the dies and pipe. 31. If necessary, lightly tap the dies until the die halves separate. Page 2611 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gauge at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Page 1121 Alignment: Service and Repair Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment 1. Ensure that the steering wheel is set in a straight ahead position. 2. Center the steering wheel position sensor prior to alignment. Refer to Steering Wheel Position Sensor Centering (See: Sensors and Switches/Sensors and Switches - Steering and Suspension/Sensors and Switches Steering/Steering Angle Sensor/Service and Repair/Steering Wheel Position Sensor Centering) 3. Loosen the tie rod jam nut (5). 4. Adjust the toe to specification by turning the adjuster (6). Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the tie rod jam nut (5) to 68 Nm (50 lb ft). Page 9868 Page 178 Locations Transmission Mode Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (MH2) 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 663 Refrigerant Pressure Sensor / Switch: Service and Repair Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure Note: Refrigerant recovery is not required. 1. Remove the refrigerant pressure sensor wire harness connector. 2. Remove the refrigerant pressure sensor. 3. Remove and discard the O-ring. Installation Procedure 1. Install a new O-ring. Refer to Air Conditioning O-Ring Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning O-Ring Seal Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the refrigerant pressure sensor and tighten to 5 Nm (44 lb in). Page 4915 1. Install the park brake cable to the vehicle. 2. Install the park brake cable and pass-through grommet (4) to the body. 3. Install the plastic retainer clip (3) to the stud. 4. Raise the vehicle. 5. Install the rear park brake cable to the caliper park brake lever. Engine Controls - MIL ON/DTC P0172 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P0172 Set TECHNICAL Bulletin No.: 10-06-04-004A Date: January 13, 2011 Subject: Intermittent Illumination of Malfunction Indicator Lamp (MIL)/Check Engine Light, DTC P0172 Set (Verify Alcohol Content Information in PCM) Models: 2010 Chevrolet Malibu Equipped with 2.4L 4 Cylinder Engine (VINs B, 0 - RPOs LE5, LE9) Please refer to GWM/IVH Supercede: This bulletin is being revised to update the engine type codes. Please discard Corporate Bulletin Number 10-06-04-004 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an intermittent illumination of the malfunction indicator lamp (MIL)/check engine light. Technicians may find a DTC P0172 set. Correction Use the procedure below to determine if the PCM has the incorrect alcohol content information. 1. Verify the actual measured percentage of alcohol content using the J-44175-A tester. Refer to Alcohol in Fuel Diagnosis in SI. If the actual alcohol is less than 15%, determine the "Fuel Alcohol Content" using the Tech 2(R). 2. Install the Tech 2(R) and build the vehicle as a 2010 and select Powertrain. 3. Build the vehicle with an LE9 engine (even if it has the LE5 engine). - Select Special Functions. - Select Fuel System (F2). Page 9111 Page 6171 Page 9547 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). OnStar(R) - Availability for Hearing Impaired Communications Control Module: Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 8340 Disclaimer Page 2901 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 1770 Tensioner/Service and Repair). 6. Install the EN-48953 - locking tool (1). 7. Install the camshaft actuator retainer bolts and tighten 10 Nm (89 lb in). 8. Tighten the NEW camshaft actuator bolt to 30 Nm (22 lb ft) plus an additional 100 degrees using the EN-45059 - meter. Note: You must have the EN-48953 - locking tool installed to perform this procedure. 9. To release the tensioner apply a counterclockwise rotational torque to the crankshaft balancer bolt of 45 Nm (33 lb ft). 10. Remove the camshaft actuator retainer EN-48953 - locking tool (1). Page 9020 * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information This product is current available from Kent Industries (1-888-YES-KENT). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5194 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Page 10054 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Page 4714 Brake Bleeding: Service and Repair Hydraulic Brake System Flushing Hydraulic Brake System Flushing Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination: * Fluid separation, indicating 2 types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system - Swirled appearance-oil-based substance - Layered appearance-silicone-based substance * Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system - Cloudy appearance - moisture - Dark appearance/suspended particles in fluid-dirt, rust, corrosion, brake dust 2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination. 3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: 1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement) * Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Front Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) * Rear Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement) 2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. 3. Dry the brake pipes using non-lubricated, filtered air. 4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated: * Master Cylinder Replacement (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement) Also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement (See: Hydraulic System/Brake Fluid Reservoir/Service and Repair). Replace the brake master cylinder reservoir cap diaphragm. * Front Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and Repair/Front Brake Hose Replacement) * Rear Brake Hose Replacement (See: Hydraulic System/Brake Hose/Line/Service and Repair/Rear Brake Hose Replacement) * Front Brake Caliper Overhaul (See: Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Front Brake Caliper Overhaul)or Front Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Front Brake Caliper Replacement) * Rear Brake Caliper Overhaul (See: Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Rear Brake Caliper Overhaul)or Rear Brake Caliper Replacement (See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement) * Brake Pressure Modulator Valve Replacement (See: Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, Page 6813 The Z height dimension measurement determines the proper ride height for the front end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. Use the following procedure to check the Z height dimension: 1. Using your hands, lift the front bumper approximately 38 mm (1.59 in). 2. Gently remove your hands and allow the vehicle to settle. 3. Repeat the jouncing operation a total of 3 times. 4. You will need 2 measurements to compute the Z height. Measurement 1 should be taken from the bottom edge of the support flange (X) to the ground line. Measurement 2 should be taken from the bottom edge of the lowest point of the ball stud (Y) to the ground line. Subtract measurement 2 (Y) from measurement 1 (X). This will give you your Z height dimension. 5. Using your hands, jounce the front of the vehicle downward approximately 38 mm (1.59 in). 6. Gently remove your hands and allow the vehicle to settle. 7. Repeat the jouncing operation a total of 3 times. 8. Measure the Z height dimension. 9. The true Z height dimension number is the average of the high and the low measurements. Refer to Trim Height Specifications (See: Suspension/Specifications/Mechanical Specifications/Trim Height Specifications). D Height Measurement Page 8525 Alarm Module: Service and Repair Theft Deterrent Module Replacement Page 4035 Transmission Control Module (TCM) (MN5 with LE5 or LE9) Locations Brake Fluid Level Sensor/Switch: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 10557 Combination Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Locations Sunroof / Moonroof Module: Locations Passenger Compartment/Roof Component Views Roof/Headliner Components (CF5) 1 - Sunroof Motor (part of the Sunroof Control Module) 2 - Sunroof Control Module Page 2226 5. Remove the HO2S using the J 39194-B. 6. Remove the exhaust manifold heat shield bolts and shield. Page 3360 1. Install the MAF/IAT sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1) and tighten to 2.5 Nm (22 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor (2). Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 6911 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose Replacement Power Steering Gear Outlet Pipe/Hose Replacement Special Tools J-44586 - Power Steering Gear Oil Seal Remover/Installer Removal Procedure 1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). 2. Remove as much power steering fluid from the power steering fluid reservoir as possible. 3. Place drain pans under the vehicle as needed. 4. Compress the power steering gear outlet hose clamp (1) and disconnect the power steering reservoir inlet pipe (2) from the power steering gear outlet hose (3). 5. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). Page 6178 Fuse Block - Rear X2 Page 8980 Console: Service and Repair Front Floor Console Extension Panel Replacement - Right Side Front Floor Console Extension Panel Replacement - Right Side Page 4400 15. Crimp the seal retaining clamp (1) using J 35910 to 174 Nm (130 lb ft). 16. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Dimension a= 1.9 mm (5/64 in). Page 10115 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Page 7626 4. Remove the white plug (1) and assure there is no debris in the drain tube and/or plug. If debris exists, pull from the drain tube (do NOT force back into evaporator case) and reinstall the plug. Important Do not get sealer on the heat shield, on the end of, or within the drain tube. 5. Mask off the areas (1, 2) by the HVAC drain using high-quality automotive tape. 6. Apply high tech seam sealer, Kent Industries P/N P10200*, to the front of dash area as shown in figure below. 7. Remove the high quality automotive tape and reposition the heat shield to its normal position. 8. Lower the vehicle. Let the vehicle run with A/C on. 9. Perform a final inspection for the A/C and verify that the system is draining properly. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information This product is currently available from Kent Industries (1-888-YES-KENT). Warranty Information Page 9890 Page 9152 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 3217 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement Special Tools J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. Warning Page 1455 Fuse Block - Underhood X5 (Battery Positive Cable) (without NVH) Fuse Block - Underhood X6 (Battery Positive Cable) Page 3138 Fuel Tank Pressure Sensor: Service and Repair Fuel Tank Pressure Sensor Replacement Page 1271 Power Steering Line/Hose: Service and Repair Power Steering Fluid Reservoir Outlet Hose Replacement Power Steering Fluid Reservoir Outlet Hose Replacement Removal Procedure 1. Remove as much power steering fluid from the remote power steering fluid reservoir as possible. 2. Place drain pans under the vehicle as needed. 3. Compress the power steering fluid reservoir outlet hose clamp (1) and disconnect the power steering fluid reservoir outlet hose (2) from the remote power steering fluid reservoir (3). 4. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 5. Compress the power steering fluid reservoir outlet hose clamp (1) and disconnect the power steering fluid reservoir outlet hose (2) from the power steering pump (3). Page 5609 Transmission Control Module (TCM) (MN5 with LZ4 or LZE) Page 9620 Campaign - Airbag Readiness Light/Service Airbag Message Technical Service Bulletin # 10085D Date: 110203 Campaign - Airbag Readiness Light/Service Airbag Message CUSTOMER SATISFACTION Bulletin No.: 10085D Date: February 03, 2011 Subject: 10085D - Airbag Readiness Light/Service Airbag Message - Replace Connectors Models: 2008 Buick Enclave 2010 Chevrolet Malibu 2008 GMC Acadia 2010 Pontiac G6 2008 Saturn OUTLOOK Supercede: The Service Procedure in this bulletin has been revised. All vehicles will not require the replacement of the front seat-mounted side impact airbag connectors.Please discard all copies of bulletin 10085C, issued November 2010. Condition Certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may experience wear which could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact air bag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG System warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG System DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Correction Dealers are to replace the front seat-mounted side impact airbag connectors. Vehicles Involved Involved are certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Part Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 6900 6. Compress the power steering gear outlet hose clamp (1) and disconnect the power steering reservoir inlet hose (2) from the power steering gear outlet hose (3). 7. Remove the power steering reservoir inlet hose from the vehicle. Installation Procedure 1. Install the power steering reservoir inlet hose to the vehicle. 2. Compress the power steering gear outlet hose clamp (1) and connect the power steering gear outlet hose (3) to the power steering reservoir inlet hose (2). Page 5851 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. Page 4838 Installation Procedure Caution: This is a self-retaining fastener joint that does not require thread locking compounds. Do not attempt to clean the threads with a standard tap. If a standard tap is used, damage to the joint threads will occur. 1. Install the brake caliper mounting bracket to the steering knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the brake caliper mounting bracket bolts (1) and tighten to 130 Nm (96 lb ft). 3. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces (1) of the caliper bracket only. 4. Clean the brake pad mating surfaces of the brake pad retainers (2). 5. Install the brake pad retainers (2) to the brake caliper bracket. Restraint System - Normal Safety Belt Locking Conditions Seat Belt: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Page 10013 Page 3573 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Exhaust Camshaft Position Sensor Replacement - Exhaust Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (5) from the exhaust camshaft position (CMP) sensor (4). 3. Remove the CMP sensor bolt. (Intake CMP shown, exhaust CMP similar). 4. Remove the CMP sensor. Installation Procedure Page 6496 Brake Booster Vacuum Sensor (LAT) Page 5197 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Connector Position Assurance Locks Connector Position Assurance Locks Page 2792 Page 4551 4-3 Shift Solenoid (SS) Valve (ME7 or MN5) Control Solenoid Valve Assembly (MH2) Page 5491 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY7 or LZ4 or LZE) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LY7 or LZ4 or LZE) Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: Do not damage the exterior surface of the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use general purpose cleaner to clean the leak area. 9. Apply 3 mm (0.12 in) thick layer of adhesive/sealant to the leak area. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Specifications/Suspension). 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 13. Pressurize the tire to 276 kPa (40 psi). 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Inflate the tire to the specified pressure as stated on the tire placard. 16. Balance the tire and wheel. Refer to Tire and Wheel Assembly Balancing - Off Vehicle (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Repair Instructions/Tire and Wheel Assembly Balancing - Off Vehicle). 17. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Page 5626 Windshield Washer Fluid Level Switch Windshield Washer Fluid Pump Page 4534 2. Attach the ball-sockets to the control assembly body and the shift-lock control lever. 3. Connect the electrical connector to the Shift Lock Control Solenoid. 4. Install the automatic transaxle control assembly. Page 3390 Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (without LAT or HP7) 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 6350 Ignition Switch Page 992 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Page 2626 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor (2). 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2). Installation Procedure Locations Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Fuel Tank Components 1 - Evaporative Emission (EVAP) Canister 2 - Evaporative Emission (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly 4 - Fuel Tank Pressure (FTP) Sensor 5 - Fuel Tank Page 8307 A new microphone has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6367 Kn - Re Component Connector End Views Knock Sensor (KS) (LAT or LE5 or LE9) Locations Sunroof / Moonroof Module: Locations Passenger Compartment/Roof Component Views Roof/Headliner Components (CF5) 1 - Sunroof Motor (part of the Sunroof Control Module) 2 - Sunroof Control Module Service Precautions Catalytic Converter: Service Precautions Three-Way Catalytic Converter Damage Caution Caution: In order to avoid damaging the replacement three-way catalytic converter, correct the engine misfire or mechanical fault before replacing the three-way catalytic converter. Page 5522 Inflatable Restraint Front End Sensor - Left Inflatable Restraint Front End Sensor - Right Page 9109 Page 2148 5. Remove the radiator from the vehicle. Installation Procedure 1. Install the radiator to the vehicle. Page 1460 Fuse Block - Rear X1 Page 2965 Oxygen Sensor: Diagrams Component Connector End Views Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY7 or LZ4 or LZE) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LY7 or LZ4 or LZE) Locations Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) Service and Repair Power Distribution Relay: Service and Repair Relay Replacement Removal Procedure 1. Locate the relay. Refer to the Master Electrical Component List (See: Locations/Component Locations/A - Z Index) to locate the relay in the vehicle. 2. Remove any fasteners which hold the relay in place. 3. Remove any connector position assurance (CPA) devices or secondary locks. Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape. 4. Separate the relay (1) from the wire harness connector (2). Installation Procedure 1. Connect the relay (1) to the wire harness connector (2). 2. Install any connector position assurance (CPA) devices or secondary locks. 3. Install the relay using any fasteners or tape that originally held the relay in place. Locations Dimmer Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 209 Page 2623 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 7948 Side Air Bag: Locations Passenger Compartment/Roof Component Views Seat Side Components - Driver and Passenger 1 - Inflatable Restraint Side Impact Module - Left 2 - Inflatable Restraint Side Impact Module - Right Page 242 Fuse Block - Rear Bottom View Page 8774 1. Install the power window motor bolts to the window regulator and tighten to 6 Nm (53 lb in). 2. Install the window regulator and motor through the access opening. 3. Install the front door window regulator. Refer to Front Side Door Window Regulator Replacement (See: Windows and Glass/Windows/Service and Repair/Removal and Replacement/Front Side Door Window Regulator Replacement). 4. Connect the electrical connector (2) to the power window motor. 5. Remove the masking tape. Lower the window far enough in order to gain access to the bolts (1, 2) that attach the window to the regulator. 6. Install the bolts (1, 2) that attach the window to the regulator and tighten to 10 Nm (89 lb in). 7. Inspect the window for proper operation. 8. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Front Door Panel/Service and Repair/Front Side Door Water Deflector Replacement). 9. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair/Front Side Door Trim Panel Replacement). Locations Camshaft Position Sensor: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch Page 903 Camshaft Position (CMP) Sensor - Intake (LAT or LE5 or LE9) Page 4409 3. Reconnect the wheel speed senor electrical connector, if needed. 4. Install the wheel speed sensor electrical connector on the retaining bracket, if needed. 5. Install the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 6. Install the wheel drive shaft retaining nut and washer. Refer to Wheel Drive Shaft Replacement (See: Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement). 7. Remove the support and lower the vehicle. Page 4841 1. Install the brake caliper bracket. Caution: This is a self-retaining fastener joint that does not require thread locking compounds. Do not attempt to clean the threads with a standard tap. If a standard tap is used, damage to the joint threads will occur. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the brake caliper mounting bracket bolts (2) and tighten to 130 Nm (96 lb ft). 3. Install the brake pad retainers (2) to the brake caliper bracket (3). 4. Install the brake pads (1) to the brake caliper bracket (3). 5. Install the brake caliper. Refer to Rear Brake Caliper Replacement (See: Rear Brake Caliper Replacement). 6. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 7. Lower the vehicle. 8. Pump the brake pedal 2-3 times in order to seat the rear disc brake pads to the rotor. Page 9209 Page 2497 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Page 2775 4. Connect the body wiring harness electrical connector (1) to the ECM. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 6. Program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Page 9514 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Page 578 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 3871 1. Remove the piston pin assembly from the servo cover. 2. Remove the snap ring (70) from the servo pin. 3. Remove the piston (77) and the servo cushion springs (75) from the servo pin. 4. Remove the servo piston seals from the cover (78, 79). 5. Discard the servo piston seals. 6. Inspect all components for damage. 7. Inspect the fluid feed holes for the proper opening. 8. Inspect the bolt hole threads for debris or stripping. 9. Inspect the seal grooves for damage. 10. Clean and dry each component. Assembly Procedure 1. Assemble the servo cushion springs (75) and the servo piston (77) onto the servo pin (76). 2. Install the snap ring (70) onto the servo pin in order to retain the servo cushion springs and servo piston. 3. Assemble new seals (78, 79) onto the servo piston and servo cover. Page 4364 8. Remove the ball bearings from the CV joint in sequence. Important: Position the cage so that the larger radius corners of the cage windows are facing up. 9. Position the cage (1) at 90 degrees to the centerline of the outer race. 10. Align the cage windows with the lands of the outer race. 11. Lift and remove the cage and the inner race from the outer race. Page 6544 X801 Inline Harness Connector End Views X801 Right Rear Door Harness to Right Rear Door Trim Pad Harness X900 - X999 Inline Harness Connector End Views Page 7310 13. Use the tire changer in order to install the tire to the wheel. Warning To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. 14. Inflate the tire until it passes the bead humps. Be sure that the valve core is not installed at this time. 15. Install the valve core to the valve core stem. 16. Inflate the tire to the proper air pressure. 17. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Page 10081 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 5394 Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake (LY7) Page 5257 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Power Outlet Schematics I/P and Center Console Outlet 110V AC Outlet (KV1) Page 9695 GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The Page 5597 Sunroof Switch (CF5) Page 6335 HVAC Control Module X1 (C60) HVAC Control Module X1 (C68) Engine Controls - MIL ON/DTC P0172 Set Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P0172 Set TECHNICAL Bulletin No.: 10-06-04-004A Date: January 13, 2011 Subject: Intermittent Illumination of Malfunction Indicator Lamp (MIL)/Check Engine Light, DTC P0172 Set (Verify Alcohol Content Information in PCM) Models: 2010 Chevrolet Malibu Equipped with 2.4L 4 Cylinder Engine (VINs B, 0 - RPOs LE5, LE9) Please refer to GWM/IVH Supercede: This bulletin is being revised to update the engine type codes. Please discard Corporate Bulletin Number 10-06-04-004 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an intermittent illumination of the malfunction indicator lamp (MIL)/check engine light. Technicians may find a DTC P0172 set. Correction Use the procedure below to determine if the PCM has the incorrect alcohol content information. 1. Verify the actual measured percentage of alcohol content using the J-44175-A tester. Refer to Alcohol in Fuel Diagnosis in SI. If the actual alcohol is less than 15%, determine the "Fuel Alcohol Content" using the Tech 2(R). 2. Install the Tech 2(R) and build the vehicle as a 2010 and select Powertrain. 3. Build the vehicle with an LE9 engine (even if it has the LE5 engine). - Select Special Functions. - Select Fuel System (F2). Page 8981 Console: Service and Repair Front Floor Console Bracket Replacement Front Floor Console Bracket Replacement Service and Repair Trunk / Liftgate Shock / Support: Service and Repair Rear Compartment Lid Strut Replacement Description and Operation Variable Valve Timing Actuator: Description and Operation Camshaft Actuator System Description Camshaft Position (CMP) Actuator System The camshaft position (CMP) actuator system is an electro-hydraulic operated device used for a variety of engine performance and operational enhancements. These enhancements include lower emission output through exhaust gas dilution of the intake charge in the combustion chamber, a broader engine torque range, and improved fuel economy. The CMP actuator system accomplishes this by changing the angle or timing of the camshaft relative to the crankshaft position. The CMP actuator simply allows earlier or later intake and exhaust valve opening during the four stroke engine cycle. The CMP actuator cannot vary the duration of valve opening, or the valve lift. During engine OFF, engine idling conditions, and engine shutdown, the camshaft actuator is held in the Park position. Internal to the CMP actuator assembly is a return spring and a locking pin. During non-phasing modes of the camshaft, the return spring rotates the camshaft back to the Park position, and the locking pin retains the CMP actuator sprocket to the camshaft. CMP Actuator System Operation The camshaft position (CMP) actuator system is controlled by the engine control module (ECM). The ECM sends a signal to a CMP actuator solenoid in order to control the amount of engine oil flow to a Cam Actuator passage. The pressurized engine oil is sent to unseat the locking pin, and to the vane and rotor assembly of the CMP actuator. There are 2 different passages for oil to flow through, a passage for cam advance and a passage for cam retard. The Cam Actuator is attached to a camshaft and is hydraulically operated in order to change the angle of the camshaft relative to crankshaft position (CKP). Engine oil pressure (EOP), viscosity, temperature and engine oil level can have an adverse affect on Cam Actuator performance. Diagrams License Plate Lamp: Diagrams Component Connector End Views License Lamp Page 239 Page 6471 Audio Amplifier X2 (UQ3) Service and Repair Fog/Driving Lamp Bulb: Service and Repair Front Fog Lamp Bulb Replacement Page 9909 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 2. Remove the engine cover, if required. 3. Remove the fuel rail service port cap. 4. Wrap a shop towel around the fuel rail service port and using a small flat bladed tool, depress (open) the fuel rail test port valve. 5. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 6. Install the fuel rail service port cap. 7. Install the engine cover, if required. 8. Tighten the fuel fill cap. A/C - Front/Rear Passenger Carpet Wet Evaporator Drain Tube: All Technical Service Bulletins A/C - Front/Rear Passenger Carpet Wet TECHNICAL Bulletin No.: 09-01-37-002D Date: September 27, 2010 Subject: Water Leak into Front and Rear Passenger Floor and/or Carpet Wet (Inspect White Plug in HVAC Evaporator Drain and Apply Sealer to Front of Dash Area) Models: 2008-2010 Chevrolet Cobalt 2008-2011 Chevrolet HHR, Malibu 2008-2010 Pontiac G5 2008-2009 Pontiac G6 2008-2009 Saturn AURA Supercede: This bulletin is being revised to add the Pontiac G5 model. Please discard Corporate Bulletin Number 09-01-37-002C (Section 01 - HVAC). Condition Some customers may comment that the front and rear floor carpet is wet on the passenger side. Cause This condition may be caused by a plugged HVAC evaporator Drain. In some cases, water from the HVAC system will drain back though the front of the dash. Correction Note Reposition of the heat shield is not necessary on a Cobalt and HHR. 1. Verify the customer's concern. If there is water on the passenger side front floor area, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Inspect the operation of the drain. Note Make sure that small debris is not plugging up the drain. 3. Reposition the heat shield (1) in order to gain access to the HVAC drain. Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: Customer Interest Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Brake Pedal Position Sensor Calibration Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Calibration Brake Pedal Position Sensor Calibration Calibration Criteria Important: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor (BPPS) calibration must be repeated. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or body control module (BCM) have been serviced. The calibration procedure will set the brake pedal position sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via the GMLAN communication bus. Calibration Procedure 1. Apply the parking brake. 2. Place the transmission in the PARK position. 3. Install a scan tool. 4. Clear all BCM DTCs before proceeding. 5. Navigate to the Vehicle Control Systems menu. 6. Select Module Setup menu item. 7. Select BCM menu item. 8. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen. Page 5417 Digital Video Disc (DVD) Control Module X6 (SPO Accessory) (UJ5) HVAC - Automatic Control Module HVAC: Service and Repair HVAC - Automatic HVAC Control Module Replacement HVAC Control Module Replacement Blower Motor Control Processor Replacement Blower Motor Control Processor Replacement Page 6904 Power Steering Line/Hose: Service and Repair Power Steering Gear Inlet Pipe/Hose Replacement Power Steering Gear Inlet Pipe/Hose Replacement Special Tools J 44586 Power Steering Gear Oil Seal Remover/Installer Removal Procedure 1. Remove the power steering pump pulley. Refer to Power Steering Pump Pulley Replacement (See: Power Steering Pump/Service and Repair/Power Steering Pump Pulley Replacement). 2. Remove the drive belt idler pulley. Refer to Drive Belt Idler Pulley Replacement (). 3. Hoist the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 4. Remove as much power steering fluid from the power steering fluid reservoir as possible. 5. Place drain pans under the vehicle as needed. 6. Remove the 3 engine lift bracket bolts (1) and engine lift bracket (2). Page 5453 Engine Control Module (ECM) X2 (LZ4 or LZE) Locations Wiper Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 6289 Engine Coolant Temperature (ECT) Sensor (LY7) Page 7140 Second Design - Black Painted (DO NOT Lube) Hydraulic Assist Power Steering First Design - Bare Steel Tube (Lube OK) Second Design - Black Painted (DO NOT Lube) In the unlikely event that the source of the noise is identified as a second design shaft with black painted tube, it must be replaced. Correction 1 (Only for First Design - DO NOT USE FOR 2ND DESIGN) Lubricate the intermediate shaft with steering column shaft lubrication kit, P/N 26098237. 1. From inside the vehicle, remove the instrument panel insulator panel - left side panel to gain access to the intermediate shaft. 2. Remove the intermediate shaft to steering column attachment bolt. 3. Remove the intermediate shaft from the steering column. 4. Extend the intermediate shaft all the way. Using the intermediate shaft grease kit, P/N 26098237, inject the grease into the gap between the inner shaft and the outer shaft as you are collapsing the shaft. This will draw the grease into the shaft. 5. Cycle the shaft up and down several times to distribute the grease. Important Remove original thread locker material from the bolt and apply Loctite(R) 242 (or equivalent) to the threads of the bolt and reinstall intermediate shaft bolt. 6. Install the intermediate shaft to the column. Tighten - For electronic power steering, tighten the bolt to 49 Nm (36 lb ft). - For hydraulic power steering, tighten the bolt to 62 Nm (46 lb ft). Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 1999 20. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft. 21. Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten the adjustable timing chain guide bolt to 10 Nm (89 lb in). Note: Always install NEW actuator bolts. 22. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link. Page 1624 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 3036 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 8803 Rear Door Panel: Service and Repair Rear Side Door Water Deflector Replacement Rear Side Door Water Deflector Replacement Page 1041 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Component Location Component Location Component Locations 1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear Support Assembly Page 6194 Page 8762 Front Door Weatherstrip: Service and Repair Front Door Opening Weatherstrip Replacement Front Door Opening Weatherstrip Replacement Page 1877 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 11. Tighten the transaxle mount bolts (1) in the following sequence. 1. Rear 2. Front 3. Middle Tighten the bolts to 45 Nm (33 lb ft). 12. Tighten the engine mount to bracket bolts (1) in the following sequence. 1. Rear 2. Front Tighten the bolts to 50 Nm (37 lb ft). Page 7964 3. Disconnect the seat to body harness connector (1). Disconnect the seat airbag connector (2). Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing into the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Slide the conduit away on the seat airbag harness and remove just enough tape on the body harness to access the wires to install the terminals and seals. Note Use caution when stripping insulation. Take care not to cut through the wire strands. 5. Slide the wire seals onto all four leads back enough to enable removal of the insulation. Install the blue seals (1) on the body harness and the white seals (2) on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 9658 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Locations Sunroof / Moonroof Switch: Locations Passenger Compartment/Roof Component Views Roof/Headliner and Overhead Console Components 1 - Dome/Reading Lamps 2 - Center Console Flood Lamp 3 - Sunshade - Right 4 - Vanity Mirror Lamp - Right (2TL or LTZ) (Part of Sunshade - Right) 5 - Garage Door Opener (GDO) (UG1) 6 Courtesy/Reading Lamps - Right Front 7 - Sunroof Switch (CF5) 8 - Courtesy/Reading Lamps Left Front 9 - Vanity Mirror Lamp - Left (2TL or LTZ) (Part of Sunshade - Left) 10 - Sunshade - Left 11 - Cellular Telephone Microphone (UE1) Page 6244 Digital Video Disc (DVD) Control Module X4 (SPO Accessory) (UJ5) Service and Repair Maintenance Required Lamp/Indicator: Service and Repair SERVICE VEHICLE SOON or SERVICE ENGINE SOON INDICATOR If your vehicle is equipped with a "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator. This indicator is not a maintenance indicator and does not mean a maintenance service is required. For additional "SERVICE VEHICLE SOON"or a "SERVICE ENGINE SOON" indicator information refer to Malfunction Indicator Lamp. For Maintenance Required Lamp/Indicator, refer to Oil Change Reminder Lamp. Page 5251 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the MYLAR tape. If the MYLAR tape is damaged, use 3M product AL-36FR to replace the damaged MYLAR tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Page 9980 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools Page 1804 Note: Ensure that the EN 45680-882 set gauge ring surfaces are clean. 6. Carefully position EN 45680-881 trim tool assembly onto the EN 45680-882 set gauge ring. 7. Loosen the shaft collar screw (2). 8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3). Note: Once this procedure is done, it is not necessary to reset the EN 45680-881 trim tool assembly height until the blades are worn or damaged. 9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw to 19 Nm (14 lb ft). 10. Place the EN 45680-881 trim tool assembly onto the cylinder to be trimmed with the directional arrow pointing in line with the crankshaft centerline and the front of the block. 11. Install the EN 45680-884 4 bolts into the cylinder head bolt holes in the block and tighten to 20 Nm (15 lb ft). Page 4205 4. Remove the transmission range selector cable bracket bolts (1). 5. Remove the transmission range selector cable bracket (2). Installation Procedure 1. Install the transmission range selector cable bracket (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission range selector cable bracket bolts (1) and tighten to 25 Nm (18 lb ft). Page 6355 Inflatable Restraint Sensing and Diagnostic Module (SDM) Page 5646 Automatic Transmission Auxiliary Fluid Pump Control Module (HP7 with ME7) Page 7308 6. Position the wheel and tire so the valve stem is again at the 7 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the inner tire bead up and over the mounting/dismounting head. 7. Remove all residual liquid sealant from the inside of the tire and wheel surfaces. If any tire sealant is noted upon tire dismounting on vehicles equipped with TPM, replace the tire pressure sensor. Refer to Tire Pressure Indicator Sensor Replacement (See: Sensors and Switches - Wheels and Tires/Tire Pressure Sensor/Service and Repair). 8. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Caution: When mounting the tires, use an approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A silicon base compound can cause the tire to slip on the rim. A corrosive type compound can cause tire or rim deterioration. 9. Apply mounting lubricant to the tire bead and the wheel rim. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Suspension/Specifications/Fluid Type Specifications). 10. Position the rim so the valve stem (1) is at the 7 o'clock position relative to the head (2). This will protect the sensor when the bottom bead seats. Page 5721 Page 3299 12. Disconnect the EVAP canister line quick connect fitting (2) from the EVAP canister vent solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 13. Insert and gently push a small flat-bladed tool between the EVAP canister vent solenoid and the retaining bracket, disengaging the retaining tab (1). Page 788 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. (Intake CMP shown, exhaust CMP similar). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect engine wiring harness electrical connector (5) to the exhaust CMP sensor (4). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 3600 * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications (See: Specifications). An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Specifications). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Spark Plug Visual Inspection * Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak coils * Worn ignition wires Page 5219 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 1758 Note: Used roller followers MUST be returned to the original position on the camshaft. If the camshaft is being replaced, the roller followers actuated by the camshaft must also be replaced. 4. Position the roller followers on the tip of the valve stem and on the lash adjuster. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). 5. Install the exhaust camshaft (3). Lubricate with Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). Page 10591 Window Switch - Passenger Page 9884 Page 2918 Circuit/System Description The serial data is transmitted on two twisted wires that allow speeds up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the engine control module (ECM) and the other can be a separate resistor in a connector assembly or in another control module. The resistors are used as the load for the High Speed GMLAN buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level of approximately 2.5 V. Driving the lines to their extremes, adds one volt to the high speed GMLAN serial data bus (+) circuit and subtracts one volt from the high speed GMLAN serial data bus (-) circuit. If serial data is lost, control modules will set a no communication code against the non-communicating control module. Note that a loss of serial data DTC does not represent a failure of the module that set it. Diagnostic Aids * Sometimes, while diagnosing a specific customer concern or after a repair, you may notice a history U-code present. However, there is no associated "current" or "active" status. Loss-of-communication U-codes such as these can set for a variety of reasons. Many times, they are transparent to the vehicle operator and technician, and/or have no associated symptoms. Eventually, they will erase themselves automatically after a number of fault-free ignition cycles. This condition would most likely be attributed to one of these scenarios: - A control module on the data communication circuit was disconnected while the communication circuit is awake. - Power to one or more modules was interrupted during diagnosis - A low battery condition was present, so some control modules stop communicating when battery voltage drops below a certain threshold. - Battery power was restored to the vehicle and control modules on the communication circuit did not all re-initialize at the same time. - If a loss-of-communication U-code appears in history for no apparent reason, it is most likely associated with one of the scenarios above. These are all temporary conditions and should never be interpreted as an intermittent fault, causing you to replace a part. * Do not replace a control module reporting a U-code. The U-code identifies which control module needs to be diagnosed for a communication issue. * Communication may be available between the BCM and the scan tool with the high speed GMLAN serial data system inoperative. This condition is due to the BCM using both the high and low speed GMLAN systems. * An open in the DLC ground circuit terminal 5 will allow the scan tool to operate but not communicate with the vehicle. When the scan tool attempts to communicate with the vehicle a message "no CANdi module detected" will be displayed. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. * Technicians may find various Local Area Network (LAN) communication Diagnostic Trouble Codes (DTC) and no low speed GMLAN communications with the scan tool. * The engine will not start when there is a total malfunction of the high speed GMLAN serial data bus. These conditions may be caused by the installation of an aftermarket navigation radio module (see bulletins). Some customers may comment of one or more of the following concerns: - Vehicle will not crank. - Vehicle cranks but will not start. - Vehicle stability enhancement system warning lights and messages. - PRNDL gear indicator position errors. - Tire Pressure Monitor (TPM) system warning lights. Reference Information Schematic Reference * Data Communication Schematics (See: Diagrams/Electrical Diagrams) * Control Module References (See: Testing and Inspection/Programming and Relearning) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Page 8313 A new microphone has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8609 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Capacity Specifications Fluid - A/T: Capacity Specifications TRANSMISSION FLUID CAPACITY 4T45-E Bottom Pan Removal .............................................................................................................. .............................................................. 6.6 liters (7.0 quarts) Complete Overhaul ............................. .................................................................................................................................................. 9.0 liters (9.5 quarts) Dry ........................................................................................................................... ......................................................................... 12.2 liters (12.9 quarts) 6T40 / 6T45 Valve Body Cover Removal ..................................................................................................................................................... 5.0-7.0 liters (5.3-7.4 quarts) Fluid Change - Drain Plug ....................................................................................................................................................... 4.0-6.0 liters (4.2- 6.3 quarts) Overhaul ............................................................................................... .................................................................................... 8.0-8.5 liters (8.5-9.0 quarts) 6T70 / 6T75 Valve Body Cover Removal ..................................................................................................................................................... 5.0-7.0 liters (5.3-7.4 quarts) Fluid Change - Drain Plug ....................................................................................................................................................... 4.0-6.0 liters (4.2- 6.3 quarts) Overhaul ............................................................................................... .................................................................................... 7.0-9.0 liters (7.4-9.5 quarts) NOTE: All capacities are approximate. When adding, be sure to fill to the approximate level. Recheck fluid level after filling. Page 2698 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor. Installation Procedure Page 2320 - Select Fuel Composition Reset (F1). - The first parameter is "Fuel Alcohol Content" displayed as a percentage. If the Fuel Alcohol Content percentage is above 25%, this is the probable cause of DTC P0172. - From this screen the "Fuel Alcohol Content" can be reset to zero by pressing the lower right Tech 2(R) button. It will then display 0% when it's reset. Finally, reprogram the PCM with the latest calibration. This will correct for the PCM alcohol calculations. Note The PCM must be reset from this screen. It does not reset to zero when the PCM is reprogrammed. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 10797 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 6420 Starter Generator Control Module (SGCM) X4 (LAT) Starter Generator Control Module (SGCM) X5 (LAT) Starter Generator Control Module (SGCM) X6 (LAT) Starter Generator Control Module (SGCM) Coolant Pump (LAT) Page 3841 Shift Solenoid: Specifications 6T70/6T75 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Page 10614 Window Switch - Passenger Page 6850 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become UN-centered and cause possible damage to the SIR coil. If you think the SIR coil has became UN-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (without LAT or HP7) 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 5986 Page 9751 For vehicles repaired under warranty use the table above. Disclaimer Page 2912 Low Speed Serial Data Page 1588 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage Page 6832 Steering Control Module: Diagrams Component Connector End Views Electric Power Steering (EPS) Module X1 (without NVH) Electric Power Steering (EPS) Module X2 (without NVH) Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ........................................ 345-414 kPa (50-60 psi). Verify the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute Page 4844 1. Lubricate the new piston seal (4) with GM approved or equivalent brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal (4) into the caliper bore. 3. Apply a thin coat of GM approved or equivalent brake fluid from a clean, sealed brake fluid container onto the outer surface area of the caliper piston (3). 4. Install the bottom half of the caliper piston (2) into the caliper bore. 5. Install the new piston dust boot seal (1) over the caliper piston (2). 6. Compress the caliper piston (2) to the bottom of the caliper bore. 7. Fully seat the piston dust boot seal (1) into caliper counterbore. 8. Install the retaining ring that secures the dust boot to the caliper housing. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the bleeder valve to the caliper and tighten the valve to 11 Nm (97 lb in). 10. Install the bleeder valve cap. Mobile Telephone and Navigation Antenna Coaxial Cable Replacement Antenna Cable: Service and Repair Mobile Telephone and Navigation Antenna Coaxial Cable Replacement Mobile Telephone and Navigation Antenna Coaxial Cable Replacement Removal Procedure 1. Lower the headliner from the vehicle. Refer to Headlining Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). 2. Remove the right closeout panel. Refer to Instrument Panel Insulator Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement Right Side). 3. Disconnect the cable from the antenna. 4. Disconnect the cable from the communications module. 5. Remove the cable from the vehicle. Page 6034 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Instrument Panel Outer Air Outlet Replacement - Left Side Air Register: Service and Repair Instrument Panel Outer Air Outlet Replacement - Left Side Instrument Panel Outer Air Outlet Replacement - Left Side Page 834 Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (LAT or LE5 or LE9) Manifold Absolute Pressure (MAP) Sensor (LY7) Page 8590 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 461 Transmission Control Module (TCM) (MN5 with LE5 or LE9) Page 7663 Locations Pedal Positioning Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 4598 Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover Replacement). 13. If a NEW TCM has been installed into the vehicle, the NEW module needs to be reprogrammed. Refer to Service Programming System (SPS) ( See: Testing and Inspection/Programming and Relearning/Service Programming System (SPS)). Note: The Service Fast Learn Adapts procedure must be performed when one of the following repairs have been made to the vehicle. Failure to perform the procedure after one of the following repairs may result in poor transmission performance, as well as transmission DTCs being set: * Transmission internal service/overhaul * Valve body repair or replacement * Control solenoid valve assembly replacement * TCM software/calibration update * Any service in response to a shift quality concern 14. Perform the Service Fast Learn Adapts. Refer to Service Fast Learn Adapts (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning/6T70/6T75 - Automatic Transmission). Page 9292 Seat Components - Passenger 1 - Seat Back Cover - Passenger 2 - Heated Seat Element - Passenger Back (KA1) 3 - Seat Back Cushion Pad - Passenger 4 - Seat Belt Switch - Passenger 5 - Seat Horizontal Motor - Passenger (1LZ) 6 - Seat Rear Vertical Motor - Passenger (1LZ) 7 - Heated Seat Control Module - Passenger (KA1) 8 - Seat Front Vertical Motor - Passenger (1LZ) 9 - Heated Seat Switch - Passenger (KA1) 10 - Seat Adjuster Switch - Passenger (1LZ) 11 - Inflatable Restraint Front Passenger Presence System (PPS) Module 12 - Seat Cushion - Passenger 13 - Heated Seat Element - Passenger Cushion (KA1) 14 - Seat Cover - Passenger Page 4391 6. Slide the tripot joint spider assembly (4) as far as it will go on the halfshaft bar. 7. Install the spacer ring (2) into the groove of the halfshaft bar J 8059. Page 3385 Fuel Injector: Diagrams Component Connector End Views Fuel Injector 1 (LAT or LE5 or LE9) Fuel Injector 1 (LY7) Page 9551 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 937 Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Front End Sensor - Left Inflatable Restraint Front End Sensor - Right Inflatable Restraint Side Impact Sensor (SIS) - Left Page 7776 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left A/C - Poor Cooling Performance/Condenser Fan Fuse Blown Fuse: Customer Interest A/C - Poor Cooling Performance/Condenser Fan Fuse Blown TECHNICAL Bulletin No.: 09-01-38-005 Date: October 09, 2009 Subject: Poor A/C Performance, Cooling Fan Fuse Blown (Install Revised Fuse And Wiring) Models: 2008-2010 Chevrolet Malibu 2006-2010 Pontiac G6 2007-2010 Saturn AURA All with RPO LY7, LZ4, LZ9 or LZE V6 Engine Condition Some customers may comment on poor A/C cooling performance. Technicians may find that the cooling fan fuse is blown. Cause High cooling fan start up loads may cause the 30-amp cooling fan fuse, located in the underhood fuse block, to blow. The lack of air flow through the A/C condenser, caused by the inoperative high-speed cooling fan, may affect the condenser's ability to dissipate heat. Correction Use the following procedure to install a heavier gauge power feed wire from the underhood fuse block to the cooling fan. After the wiring update is completed, replace the 30-amp cooling fan fuse in the underhood fuse block with a 40-amp fuse. 1. Disconnect and remove the battery. Refer to Battery Replacement in SI. 2. Remove the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 3. Disconnect the underhood fuse block from it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. It is only necessary to raise the fuse block enough to access the harness connectors. Do not remove the complete assembly from the vehicle. 4. Locate the engine wiring harness junction block assembly (X1) on the back (underside) of the underhood fuse block and disconnect it from the underhood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 5. Find pin A2, Circuit 532, cooling fan motor supply voltage. Refer to Electrical Center Identification Views, Fuse Block-Underhood X1 in SI. 6. Remove the harness back cover. Remove the TPA (terminal position assurance) clip and remove connector A2 from the junction block. Cut the terminal off and tape the wire end with electrical tape. 7. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 8. Locate the electrical connector to the right cooling fan and disconnect the wiring connector from the fan. 9. Disengage pin B, wire 3 GY, circuit 532, cooling fan motor supply voltage, from the connector housing (pull to seat terminal). Cut the terminal off of the wire and remove the wire from the connector housing. 10. Tape the end of the wire with electrical tape. 11. Prepare a 1.82 m (6 ft) section of automotive grade 5.0 mm (10 GA) wire and an equal length of 6 mm (1/4 in) flexible plastic conduit, GM P/N 12051375. 12. Run the new wire through the fan wire connector housing as shown. 13. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 14. Strip the wire insulation as required and install the terminal, GM P/N 12033997, on the wire. Secure the wire and terminal into the fan wire Page 2045 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Inlet Duct Replacement Air Cleaner Inlet Duct Replacement Page 5981 Page 9673 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 8277 GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The Page 3358 Page 3592 Knock Sensor (KS) 2 (LZ4 or LZE or LY7) Page 4627 4. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 5. Install the shift control cable to transaxle range switch lever and verify proper operation. Page 7933 Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a Customer Satisfaction Program that affects your 2010 model year Chevrolet Malibu or Pontiac G6. We have learned that your 2010 model year Chevrolet Malibu or Pontiac G6 may have a condition in which wear could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact airbag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG system warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG system DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Your Malibu or G6 may have been serviced previously to reroute and secure both front seat-mounted side impact airbag wire harnesses. However, there have been reports of the SERVICE AIR BAG message illuminating in the Driver Information Center (DIC) on vehicles that had the wire harnesses rerouted and secured, but did not have new connectors installed. Our records indicate that your vehicle may not have had the new connectors installed. What We Will Do: Since your vehicle may not have had new connectors installed, your GM dealer will inspect your vehicle to determine if new connectors have been installed, and will install two new connectors, if required. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 11034 Page 6067 For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. Page 6242 Digital Video Disc (DVD) Control Module X2 (SPO Accessory) (UJ5) Page 2873 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 4624 Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 4. Remove the transaxle range switch lever nut and lever. 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. Page 8257 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Diagrams Ignition Control Module: Diagrams Component Connector End Views Ignition Control Module (ICM) (LZ4 or LZE) Page 2259 1. Install the exhaust manifold heat shield. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust manifold heat shield bolts and tighten to 10 Nm (89 lb in). 3. Install the bank 1 sensor 1 HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (). Exhaust Manifold Heat Shield Replacement - Left Side Exhaust Manifold Heat Shield Replacement - Left Side Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). Page 10031 Page 6719 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 1221 6. Remove the refrigerant filter from the line. Note: Cap all A/C components immediately to prevent system contamination. 7. Remove and discard the sealing washers. Installation Procedure 1. Uncap A/C components. 2. Install new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 3. Install the refrigerant filter into the line. 4. Install the line clip to the dash. Page 5542 Manifold Absolute Pressure (MAP) Sensor (LY7) Page 2359 Page 739 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement Service and Repair Body / Frame Mount Bushing: Service and Repair Drivetrain and Front Suspension Frame Insulator Replacement Tools Required J-45725 Frame Bushing Installer Removal Procedure 1. Remove the frame. Refer to Frame Replacement (See: Service and Repair). 2. Remove cradle bushing with a rubber mallet. Installation Procedure 1. Install clamp J-45725 onto the bushing leaving about an 1/8 inch from the bottom of the bushing. Page 6361 Inflatable Restraint Steering Wheel Module Coil X1 Page 6757 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6454 Window Switch - Right Rear Page 6607 Page 6684 6. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals on to the bare wire using the J38125-7 crimp tool, jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 7. Position the wire seal to the terminal and crimp the seal and insulation using the J-38125-6 crimp tool, jaw 1 (1). The completed terminal and seal should appear as shown above (body harness connector shown). Note Avoid getting solder on the terminal end or overheating the terminal. Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. 8. Solder all four terminals at the wire crimp. 9. Slide the two body harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Air Cleaner Outlet Duct Replacement Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement Page 5795 Fuse Block - Rear X4 Page 9563 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Service and Repair Child Seat Tether Attachment: Service and Repair Child Restraint Tether Anchor Replacement Page 9128 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Page 8259 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Locations Trunk / Liftgate Switch: Locations Door Component Views Driver Door Components 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Page 7496 Page 2477 5. Remove the fuel injector wiring harness clips (1) from the fuel rail tabs. 6. Disconnect the fuel injector wiring harness electrical connector (2) from the number 3 fuel injector. 7. Squeeze tabs and slide the MAP sensor (1) upward. Installation Procedure Basecoat/Clearcoat Paint Systems Paint: Application and ID Basecoat/Clearcoat Paint Systems Basecoat/Clearcoat Paint Systems Warning Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. All paint finish repairs of rigid exterior surfaces must meet GM standards. Refer to the latest revision of GM Approved Refinish Materials to identify the paint systems you may use that have been engineered to meet GM standards. The GM Approved Refinish Materials supplies all approved products, including volatile organic compound (VOC) compliant regulations recommended by the individual manufacturer, and detailed procedures for materials used in their paint system. The latest revision of GM Approved Refinish Materials is located on the Goodwrench website at www.gmgoodwrench.com. Page 1592 Tires: Description and Operation Tire Inflation Description Tire Inflation Description This vehicle has been engineered to operate up to the stated load capacity with wheel and tire assemblies of the type, size, construction, and configuration as originally installed. Maintenance of the tire inflation pressures is critical to the continued satisfactory performance, handling, and operating economy of the vehicle. Operation with incorrectly or improperly inflated tires can adversely affect vehicle performance and may contribute to the following: * Reduced fuel economy * Tire overloading * Shortened tire life * Excessive tire wear * Uneven tire wear * Vehicle handling concerns Inspect the tire pressures when the vehicle has not been driven for at least 3 hours or not more than 1.6 km (1 mi) and when the tires are cool to the touch. Tire inflation pressures should be inspected monthly and before an extended trip and adjusted to meet the specifications listed for the particular vehicle. Replace any missing or damaged tire valve stem extensions and/or caps to prevent the intrusion of water and contaminates. One pound per square inch (psi) equals 6.9 kilopascals (kPa). The following table illustrates the conversion of kilopascals to pounds per square inch: For the correct inflation pressures refer to the vehicle's Tire Placard. Tires inflated to a higher than recommended pressure can contribute to the following conditions: * A hard ride * Tire bruising * Rapid tread wear at the center of the tire Tires inflated to a lower than recommended pressure can contribute to the following conditions: * Tire squeal on turns * Hard steering * Rapid and/or uneven wear on the outer edges of the tread * Tire rim bruises and tire rim rupture * Tire cord breakage * High tire temperatures * Sluggish vehicle handling * Higher fuel consumption Unequal pressure on the same axle can cause the following conditions: Page 1316 Note: Fluid that is very dark or black and has a burnt odor usually indicates contamination or overheating. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal particles or other debris which may indicate transmission damage. Refer to Road Test (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Initial Inspection and Diagnostic Overview/6T70/6T75 - Automatic Transmission) to verify transmission operation. Change the transmission fluid if no other conditions are found. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic Procedures/6T70/6T75 - Automatic Transmission/Engine Coolant/Water in Transmission). Page 10442 Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Center Console Components 1 - Automatic Transmission Shift Lock Control Solenoid 2 - Automatic Transmission Shift Lever Position Indicator Page 3482 Throttle Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Service and Repair Rear Door Hinge: Service and Repair Rear Side Door Upper Hinge and Lower Hinge Replacement Page 1065 Window Switch - Passenger Page 9882 Page 121 Seat Heater Control Module: Service and Repair Front Seat Heater Control Module Replacement Page 2862 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Delphi Connectors Delphi Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Diagrams Horn Switch: Diagrams Component Connector End Views Horn Switch Page 7939 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. Page 4297 25 - A/Trans Fluid Pump Seal Assembly 26 - Torque Converter with Fluid Pump Housing Assembly 27 - Torque Converter and Differential Housing Bolt 28 - A/Trans Fluid Fill Tube Plug Assembly 29 - Torque Converter Assembly Component Location Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear Page 4129 Shift Solenoid: Specifications 6T70/6T75 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Page 804 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor. Installation Procedure Page 6833 Electric Power Steering (EPS) Module X3 (without NVH) Service and Repair Transmission Shift Position Indicator Lamp: Service and Repair Automatic Transmission Control Indicator Replacement Page 4098 3 - Torque Converter Assembly 4 - Manual Shaft and Detent Lever Assembly 5 - 2nd Clutch 6 Reverse Clutch 7 - Coast Clutch 8 - Direct Clutch 9 - Reaction Planetary Gear Set 10 - Input Planetary Gear Set 11 - Forward Clutch 12 - Lo Roller Clutch 13 - Parking Lock Actuator Assembly 14 - Differential and Final Drive Assembly 15 - Output Stub Shaft 16 - Output Speed Sensor 17 Lo/Reverse Servo Assembly 18 - Lo/Reverse Band 19 - Oil Feed Tube Assembly 20 - Input Sprag Clutch Assembly 21 - Oil Filter Assembly 22 - 2nd Roller Clutch 23 - Oil Level Control Valve 24 Drive Link Assembly 25 - Driven Sprocket 26 - Output Shaft 27 - Channel Plate Assembly 28 Input Speed Sensor 29 - 4-3 Solenoid 30 - Drive Sprocket 31 - Control Valve Body Assembly 32 Oil Pump Assembly 33 - Auxiliary Pump Disassembled Views Disassembled Views Case and Associated Parts Page 3396 Fuel Injector: Testing and Inspection Fuel Injector Solenoid Coil Test Fuel Injector Solenoid Coil Test Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The control module enables the appropriate fuel injector pulse for each cylinder. The ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low will affect the engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases. Reference Information Schematic Reference Engine Controls Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Component Testing Verify the resistance of each fuel injector with one of the following methods: * If the engine coolant temperature (ECT) sensor is between 10-32°C (50-90°F), the resistance of each fuel injector should be 11-14 ohm. ‹› If the injectors measure OK, perform the Fuel Injector Balance Test. Refer to Fuel Injector Balance Test (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Injector Balance Test). ‹› If not within the specified range, replace the fuel injector. * If the ECT sensor is not between 10-32°C (50-90°F), measure and record the resistance of each fuel injector. Subtract the lowest resistance value from the highest resistance value. The difference between the lowest value and the highest value should be equal to or less than 3 ohm. ‹› If the difference is equal to or less than 3 ohm, perform the Fuel Injector Balance Test. Refer to Fuel Injector Balance Test (See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Injector Balance Test). ‹› If the difference is more than 3 ohm, add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest individual fuel injector resistance value from the average resistance value. Compute the difference between the highest individual fuel injector resistance value and the average resistance value. Replace the fuel injector that displays the greatest difference above or below the average. Repair Instructions Perform the Diagnostic Repair Verification (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Page 6257 El - Ev Component Connector End Views Electric Power Steering (EPS) Module X1 (without NVH) Page 2457 Intake Air Temperature Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 6410 Speaker - Left Front Tweeter Speaker - Left Rear (UQA) Page 8922 4. Remove the J-45725 clamp. 5. Install the bushing using the J-45725 until the lip of the bushing is fully seated to the bottom of the cradle assembly. 6. Install the frame. Refer to Frame Replacement (See: Service and Repair). Page 10233 Page 6054 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Page 225 Page 5337 Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Page 6643 Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information 1. Submit a transaction using the table below. * The amount identified in the Net Item column should represent the actual cost of the woven polyester electrical tape, required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a customer satisfaction program that affects your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle. Page 2850 6. Release the rear lower half of the wire dress cover. 7. Release the tabs that are holding the wire dress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Page 3874 6. Inspect all components for damage. 7. Inspect the fluid feed holes for proper opening. 8. Inspect the bolt hole threads for debris and stripping. 9. Inspect the seal grooves for damage. 10. Clean and dry each component. Assemble Procedure 1. Install the servo cushion springs (68) and the servo piston (77) onto the servo pin (76). 2. Install the snap ring (70) onto the servo pin (76) in order to retain the springs (68) and piston (77). 3. Install the new seals (78 and 79) onto the servo piston (77) and the servo cover (80). 4. Install the servo piston assembly into the servo cover (80). Lubricate the piston seals with transmission fluid in order to aid in assembly. Installation Procedure Steering - Front End Clunk/Rattle/Knock On Bumps Stabilizer Link: All Technical Service Bulletins Steering - Front End Clunk/Rattle/Knock On Bumps TECHNICAL Bulletin No.: 06-02-32-007G Date: April 05, 2010 Subject: Clunk, Knock or Rattle Noise From Front of Vehicle While Driving or Turning Over Bumps at Low Speeds (Diagnose Noise and Perform Outlined Repair) Models: 2004-2006 Chevrolet Malibu Maxx 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn Aura Supercede: This bulletin is being revised to update the Parts Information for the bolt. Please discard Corporate Bulletin Number 06-02-32-007F (Section 02 - Steering). Condition 1 Some customers may comment on a clunk noise heard and felt in the steering wheel while driving at slow speeds and turning. The clunk noise may appear to be directly in front of the driver. Hitting a bump while turning can produce the clunk noise. Sometimes the noise may be duplicated when the vehicle is sitting still and the steering wheel is turned 90 degrees in either direction before initially centering the steering wheel. Cause 1 The clunk noise may be caused by a slip/stick condition between the inner and outer components of the intermediate shaft. Important Revised design intermediate shafts went into production in the 2009 model year and are the only design currently available through GMSPO since approximately September 2008. Since any model year vehicle could have had a second design shaft installed, it is critical to identify it before proceeding. The revised design intermediate shafts will NOT tolerate any type of lubricant per the following instructions. Adding lube to the second design shafts will cause a clunk noise in a very short period of time. Use the following pictures to identify which design of shaft you are servicing. Electric Assist Power Steering First Design - Bare Steel Tube (Lube OK) Page 5186 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Service and Repair Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor Replacement Removal Procedure Warning Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. 1. Position the vehicle on a hoist and raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector. 3. Remove the VSS electrical harness retainer from the VSS stud. 4. Remove the VSS stud. 5. Remove the output VSS from the transmission case. Note: Inspect the O-ring for damage and replace if necessary. 6. Remove the O-ring from the VSS. Installation Procedure Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Harness: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 2605 * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Page 8193 Page 2434 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor (1) from the thermostat housing. Installation Procedure Page 9496 Page 3855 Page 1399 Page 4491 4. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 5. Install the shift control cable to transaxle range switch lever and verify proper operation. Page 3161 Page 2874 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Page 1699 Installation Procedure 1. Position the backing plate and wheel bearing/hub assembly in the steering knuckle. Page 1263 Hose/Line HVAC: Service and Repair Suction Screen Replacement Suction Screen Replacement Page 8286 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Service and Repair Vehicle Speed Sensor: Service and Repair Vehicle Speed Sensor Replacement Removal Procedure Warning Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed. 1. Position the vehicle on a hoist and raise the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Disconnect the vehicle speed sensor (VSS) electrical connector. 3. Remove the VSS electrical harness retainer from the VSS stud. 4. Remove the VSS stud. 5. Remove the output VSS from the transmission case. Note: Inspect the O-ring for damage and replace if necessary. 6. Remove the O-ring from the VSS. Installation Procedure Page 4719 7. Remove the 3 brake pedal assembly to instrument panel (I/P) carrier bolts. 8. Remove the brake pedal assembly from the vehicle. Installation Procedure 1. Install the brake pedal assembly to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the 3 brake pedal assembly to I/P carrier bolts and tighten to 25 Nm (18 lb ft). Page 786 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (7) to the intake CMP sensor (6). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 5468 Fuel Injector 1 (LZ4 or LZE) Fuel Injector 2 (LAT or LE5 or LE9) Page 5815 Your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle not only meets, but exceeds government standards for side impact protection. GM recently introduced into production, changes that add to that protection. At no charge, your dealer will make similar changes to your vehicle, which was built before the production change. What We Will Do: To enhance the side impact protection, your GM dealer will update the wiring harness for both front seat side impact airbags. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 10085 Page 3904 Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 8. Remove the control solenoid valve assembly filter plate (4). Discard the filter plate. It is not reusable. 9. Inspect the channel plate bolt pass through holes for damage or brinelling. Any damage will cause incorrect pressure switch operation. Replace as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (4) to prevent fluid leaks past the fluid seals. 2. Install the control solenoid valve assembly (3) with transmission control module. 3. Hand start the control valve body bolts (1, 2). Locations Starter Solenoid: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) Page 8269 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Page 9134 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Page 6031 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 8482 Audio Amplifier X3 (UQ3) Page 10035 Page 7619 4. Remove the white plug (1) and assure there is no debris in the drain tube and/or plug. If debris exists, pull from the drain tube (do NOT force back into evaporator case) and reinstall the plug. Important Do not get sealer on the heat shield, on the end of, or within the drain tube. 5. Mask off the areas (1, 2) by the HVAC drain using high-quality automotive tape. 6. Apply high tech seam sealer, Kent Industries P/N P10200*, to the front of dash area as shown in figure below. 7. Remove the high quality automotive tape and reposition the heat shield to its normal position. 8. Lower the vehicle. Let the vehicle run with A/C on. 9. Perform a final inspection for the A/C and verify that the system is draining properly. * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information This product is currently available from Kent Industries (1-888-YES-KENT). Warranty Information Page 5593 Starter Motor X2 (Starter to Battery) (LY7) Starter Motor X2 (Starter to Battery) (LZ4 or LZE) Starter Motor X2 (Starter to Generator) (LAT or LE5 or LE9) Starter Motor X2 (Starter to Generator) (LY7 or LZ4 or LZE) St - Ya Component Connector End Views Steering Wheel Control Switch - Left (UK3) Page 8912 Front Fender Liner: Service and Repair Front Wheelhouse Panel Splash Shield Replacement Front Wheelhouse Panel Splash Shield Replacement Page 1787 Connecting Rod: Service and Repair Piston, Connecting Rod, and Bearing Replacement Special Tools * EN-8037 - Ring Compressor * EN-24270 - Cylinder Bore Ridge Reamer * EN-43966-1 - Connecting Rod Guides * EN-45059 - Angle Meter For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the oil pan. Refer to Oil Pan Replacement (See: Engine Lubrication/Oil Pan/Service and Repair). 2. Remove the cylinder head. Refer to Cylinder Head Replacement (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement ). 3. If a ring ridge is present, remove the ring ridge as follows: 1. Turn the crankshaft until the piston is at the bottom of the stroke. 2. Place a cloth on top of the piston. 3. Use a EN-24270 - reamer to remove the ring ridge. 4. Turn the crankshaft so the piston is at top of the stroke. 5. Remove the cloth and cutting debris. Note: Place the numbers on connecting rods and the connecting rod caps. The connecting rod caps must be assembled to their original connecting rods. Page 6906 11. Remove the power steering gear inlet hose bolt (1) and disconnect the power steering gear inlet hose (2) from the steering gear. 12. Remove the power steering gear inlet hose from the vehicle. Caution: Clean the power steering gear inlet and outlet ports thoroughly of any debris. Failure to do so could result in contamination and damage to the power steering system components. 13. Install the J 44586 - remover/installer (2) to the steering gear oil seal (1). Page 5158 Page 7709 5. Install the suction hose and liquid line to the TXV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the suction hose and liquid line nut to the TXV and tighten the nut to 20 Nm (15 lb ft). 7. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 8. Leak test the fittings using the J 39400-A. 9. Install the surge tank to the surge tank bracket. Page 7064 12. Slide the left shock dampener (2) over the left inner tie rod housing (3) until the front lip of the left shock dampener bottoms against the left inner tie rod housing. 13. Slide the right shock dampener over the right inner tie rod housing until the front lip of the right shock dampener bottoms against the right inner tie rod housing. 14. Install the 2 steering gear boots. Refer to Steering Gear Boot Replacement (See: Steering Gear/Service and Repair/Steering Gear Boot Replacement). 15. Install the steering gear to the vehicle. Refer to Steering Gear Replacement (See: Steering Gear/Service and Repair/Steering Gear Replacement). Page 6130 connector housing. Refer to Repairing Connector Terminals in SI. 15. Insert the wire into the new conduit and tape the conduit end at the connector. Tape the conduit closed every 255 mm (10 in) with electrical tape. 16. Connect the fan end electrical connector into the cooling fan. 17. Fasten the new wire and conduit with tie wraps (GM P/N 12337820), as shown below. At the cooling fan end of the wire and conduit, leave adequate slack to allow for engine movement (white tie wraps are used for display purposes, use black tie wraps to match the original appearance). With RPO LY7 - Fasten the new wire and conduit to the existing harness with wire tie wraps as shown. With RPOs LZ9, LZ4 or LZE - Fasten the new wire and conduit to metal the transmission cooler lines as shown. (The lower cover has been removed to show the location of the wire tie wraps.) 18. Trim the wire and conduit to length at the underhood fuse block area. 19. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 20. Strip the wire insulation as required and install the terminal, GM P/N 15324340, on the wire. Refer to Repairing Connector Terminals in SI. 21. Reinstall the terminal into A2 on the junction block. Reinstall the TPA and the harness back cover. 22. Reconnect the harness to the under hood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 23. Reinstall the underhood fuse block into it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. Install the 40-amp fuse, GM P/N 15319478. 24. Reinstall the battery. Refer to Battery Replacement in SI. 25. Reinstall the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 26. Reinstall the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 27. Confirm the high speed cooling fan operation using the Tech 2(R). Parts Information Page 4159 9. From below, push up on the clip slot mounting tab as shown and engage the clip on the front floor console accessory trim plate. Repeat this step on the opposite side. 10. Check the shifter trim plate retention. The trim plate should not lift up just using your finger tips. If the trim plate does lift up, the retaining clips are not seated. 11. Install the left and right console side extension panels. 12. Install the shift knob. Refer to Floor Shift Control Knob Replacement in SI. 13. Place the shifter into Park ("P") and turn the ignition key to the OFF position. 14. Release the parking brake. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 10332 Fog/Driving Lamp Switch: Diagrams Component Connector End Views Fog Lamp Switch (T96) Testing and Inspection Drive Belt Tensioner: Testing and Inspection Drive Belt Tensioner Diagnosis Page 3257 Air Injection Pump: Service and Repair Secondary Air Injection Pump Replacement Page 154 Page 10260 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 2604 * Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). * Inspect for evidence of improper arcing. - Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications (See: Ignition System/Specifications). An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications (See: Ignition System/Specifications). Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. * A rattling sound indicates internal damage. * A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. - Inspect for excessive fouling. * Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. Spark Plug Visual Inspection * Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. * Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: - Rich fuel mixtures * Leaking fuel injectors * Excessive fuel pressure * Restricted air filter element * Incorrect combustion - Reduced ignition system voltage output * Weak coils * Worn ignition wires Locations Canister Purge Solenoid: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) Page 1178 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: * The drive belt * The drive belt tensioner * The drive belt idler pulley * The crankshaft balancer pulley * The accessory drive component mounting brackets * The accessory drive components - The power steering pump, if belt driven - The generator - The A/C compressor, if equipped - The engine cooling fan, if belt driven - The water pump, if belt driven - The vacuum pump, if equipped - The air compressor, if equipped The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend backward and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubber (chloroprene or EPDM) and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory. Page 1531 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Alternate Keyless Entry Transmitter or DIC Learn Enable Method 1. Ignition ON, initiate the TPM Learn Mode using one of the following procedures: * On vehicles equipped with keyless entry, simultaneously press the keyless entry transmitters lock and unlock buttons until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. * On vehicles not equipped with keyless entry, press and release the driver information center (DIC) INFO button until the TIRE LEARN message appears on the DIC display. Press and hold the SET/RESET button until a double horn chirp sounds indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, learn the tire pressure using one of the following methods: * Hold the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Warning Over inflating tires may cause personal injury or damage to the tires and wheels. When increasing tire pressure do not exceed the maximum inflation pressure as noted on the tire sidewall. * Increase/decrease the tire pressure for 8-10 seconds then wait for a horn chirp. The horn chirp may occur before or up to 30 seconds after the 8-10 second pressure increase/decrease time period has been reached. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. 3. After the horn chirp has sounded and the right front turn signal is illuminated, repeat step 2 for the remaining 3 sensors in the following order: 1. Right front 2. Right rear 3. Left rear 4. When the left rear sensor has been learned and a double horn chirp has sounded, the learn process is complete and the RCDLR exits the learn mode. 5. Ignition OFF, adjust all tires to the recommended pressures. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label ( See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Page 6331 Heater Coolant Pump (HP7) Page 4339 7. Remove the 2 control valve body bolts (4) M6 x 65. 8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95. 10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body and transmission control module (TCM) assembly (5). Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 12. Remove the control solenoid valve body assembly filter plate (6). * Discard the filler plate. It is not reusable. * Inspect the pressure switch manifold seals for damage or contamination. Replace the control solenoid valve assembly as necessary. * Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage around the bolt holes near the PCS switch feed holes could cause leakage around the PCS switch seals. Replace the upper channel plate as necessary. 13. Remove the 8 control valve body bolts (2) M6 x 65. 14. Remove the 2 control valve body bolts (1) M6 x 55. 15. Remove the manual shaft detent assembly (3). 16. Remove the control valve body assembly (4). 17. The control solenoid valve spring can now be fully removed from the lower control valve body assembly. Note: The clutch fluid passage seal is not reusable. 18. Remove the 1-2-3-4 clutch fluid passage seal (5). Installation Procedure Page 5056 1. Install the positive battery cable. 2. Raise and the vehicle. 3. Install the positive battery cable (1) to the starter solenoid. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the positive battery cable nut (3) to the starter solenoid. Tighten the nut to 10 Nm (89 lb in). 5. Lower the vehicle. 6. Install the positive battery cable to the junction block and tighten the positive battery cable bolt. Tighten the bolt to 10 Nm (89 lb in). 7. Install the positive battery cable clip (4) to the battery tray. 8. Install tape in order to secure the negative battery cable to the positive battery cable. 9. Position the positive battery cable to the battery. 10. Tighten the positive battery cable bolt to 17 Nm (13 lb ft). 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Symptoms - Cruise Control Cruise Control: Testing and Inspection Symptoms - Cruise Control Symptoms - Cruise Control Important: The following steps must be completed before using the symptom tables. 1. Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle), before using the Symptom Tables in order to verify that all of the following are true: * There are no DTCs set. * The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Cruise Control Description and Operation (See: Description and Operation). Visual/Physical Inspection * Inspect for aftermarket devices which could affect the operation of the Cruise Control System. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections ( See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). Symptom List Refer to Cruise Control Malfunction (See: Cruise Control Malfunction) in order to diagnose the system. Page 8018 Page 2526 Page 9711 * J-38125-8 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Locations Yaw Rate Sensor: Locations Passenger Compartment/Roof Component Views Roof/Headliner and Under the Center Console Components 1 - Inflatable Restraint Roof Rail Module - Right Front 2 - Inflatable Restraint Roof Rail Module Left Front 3 - Yaw and Lateral Accelerometer Sensor 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Page 6240 Digital Radio Receiver (U2K) Page 4665 Electronic Brake Control Module (EBCM) (LE5 or LE9) Page 1875 Engine Mount: Service and Repair Powertrain Mount Balancing Powertrain Mount Balancing Important: Follow the balance procedure steps listed below. Powertrain mounts must be tightened in sequence. 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 2. Remove the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair). 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Loosen the front transaxle mount through bolt (1). 5. Loosen the rear transaxle mount through bolt (1). 6. Lower the vehicle. 7. Position two floor jacks with wood blocks under the engine and transaxle in order to support the powertrain assembly. Page 9168 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 3230 Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust (LY7) Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake (LY7) Page 3366 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 5396 Camshaft Position (CMP) Actuator Solenoid Valve - Intake (LE5 or LE9) Camshaft Position (CMP) Sensor (LZ4 or LZE) Page 7894 Page 2234 8. Connect the engine wiring harness electrical connector (2) to the HO2S electrical connector. 9. Install the CPA retainer (3). 10. Install the HO2S electrical connector rosebud clip (1) to the ignition coil bracket. 11. Install the generator. Refer to Generator Replacement (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). Page 1291 2. Install the radiator outlet hose to the engine. 3. Reposition the radiator outlet hose clamp at the engine using the J 38185. 4. Install the radiator outlet hose to the radiator. 5. Reposition the radiator outlet hose clamp at the radiator using the J 38185. 6. Fill the coolant. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). Page 6579 Page 9465 Page 3710 Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 8. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. Page 9472 Page 1667 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Locations Transmission Position Switch/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components (ME7 or MN5) 1 - Park/Neutral Position (PNP) Switch Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) Electrical - Various Electrical Concerns/False Messages Door Switch: Customer Interest Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Page 2465 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) (LAT or LE5 or LE9) Knock Sensor (KS) 1 (LZ4 or LZE or LY7) Page 3250 Air Injection Hose/Tube: Service and Repair Secondary Air Injection Pipe Replacement Secondary Air Injection Pipe Replacement Page 3007 Page 1461 Page 6582 Locations Blower Motor: Locations Instrument Panel/Center Console Component Views Under the Right Side of the Instrument Panel Components 1 - Blower Motor 2 - Blower Motor Control Module (C68) 3 - Blower Motor Resistor (C60) Page 2372 4. Connect the body wiring harness electrical connector (1) to the ECM. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 6. Program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Page 971 Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor (NVH) Driver or Passenger Seat Adjuster Switch Knob Replacement Power Seat Switch: Service and Repair Driver or Passenger Seat Adjuster Switch Knob Replacement Driver or Passenger Seat Adjuster Switch Knob Replacement Page 1183 Drive Belt: Testing and Inspection Drive Belt Rumbling and Vibration Diagnosis Drive Belt Rumbling and Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. 9. Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed. 11. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smooth operation and excessive play. Compare the water pump with a known good water pump. 12. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Page 4249 6. Remove the transmission mount upper nuts from the transmission mount bracket. 7. Use the floor jack to raise the powertrain enough to remove the transmission mount. 8. Remove the transaxle mount from the frame. Installation Procedure 1. Install the transaxle mount to the frame. 2. Install the transmission mount to frame bolts. Hand tighten only. 3. Use the jackstand to lower the transmission mount bracket on to the transmission mount studs. Page 6953 1. Slide the steering wheel position sensor into place and remove the locating pin. 2. Connect any electrical connectors as needed. 3. Connect the intermediate steering shaft to the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 4. Remove anti-rotation pin J 42640. Page 718 Page 10492 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 5980 Locations Control Module HVAC: Locations Instrument Panel/Center Console Component Views Under the Right Side of the Instrument Panel Components 1 - Blower Motor 2 - Blower Motor Control Module (C68) 3 - Blower Motor Resistor (C60) Page 5784 Fuse Block - Underhood X5 (Battery Positive Cable) (without NVH) Fuse Block - Underhood X6 (Battery Positive Cable) Page 6988 7. Wipe off any excessive grease on the intermediate shaft to avoid damage from drips on the carpet. 8. Install the instrument panel insulator panel - left side. 9. Verify that the noise is no longer present. Condition 2 There may be interference between the clamp and the steering gear input shaft. The clamp is beveled and if forced down on the input shaft too hard, it may cause a loose fit with the intermediate shaft to input shaft joint. Correction 2 To correct this condition, perform the following steps: 1. Remove the intermediate shaft pinch bolt at the steering gear end. 2. Install a new bolt, GM P/N 07845238, but do not tighten the bolt at this time. 3. Pry the clamp up using a pry bar to position the bolt into the upper part of the groove as shown above. This will position the clamp off the bevel. 4. While keeping the clamp in the upper position, tighten the bolt. Tighten Tighten the bolt to 49 Nm (36 lb ft). 5. Verify that the clunk noise is no longer present. Condition 3 Important This condition ONLY applies to 2004-2007 Chevrolet Malibu/Maxx and 2005-2007 Pontiac G6. Some customers may comment on a knocking or rattling type noise from the front of the vehicle when driven at low speeds and over bumps. The noise only occurs when the steering wheel is in the straight ahead position and sounds like the noise is in the left suspension of the vehicle or directly in front of the driver. Correction 3 1. Ensure the noise is not caused by Condition # 1. 2. Determine the source of the noise. Install the chassis ears at the following locations: - sway bar link - one side at a time - upper strut mount - one side at a time - steering gear near the pinion area - base of the steering column housing - radiator surge tank 3. If the noise is coming from the upper strut mount or sway bar link, replace as necessary and retest. 4. For 2004-2006 Chevrolet and Pontiac model year vehicles, the noise may be coming from the radiator surge tank area. (The 2007 model year vehicles use a different style radiator surge tank - refer to Step 9.) 5. If the noise is coming from the radiator surge tank, release the two retaining tabs holding the radiator surge tank and reposition the tank away from the attaching bracket and isolate with closed cell foam. 6. Cut three pieces of closed cell foam, P/N P46515 (or equivalent), into 25 mm (1 in) by 102 mm (4 in) pieces. 7. Cut two pieces of closed cell foam into 25 mm (1 in) by 6 mm (1/4 in) pieces. Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder Replacement Page 9505 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Page 4547 13 - Front Differential Transfer Driven Gear 14 - Front Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual Valve Disassembled Views Disassembled Views Case and Associated Parts Locations Central Control Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 6155 Fuse: Application and ID Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 10577 Page 4208 6. Disconnect the transmission range selector lever cable terminal (2) from the shift lever pin. 7. Release the transmission range selector lever cable retainer (1) and remove the transmission range selector cable from the transmission control lever base. 8. Release the transmission range selector lever cable retainer. Page 5615 Vehicle Communication Interface Module (VCIM) X3 (UE1) Locations Crankshaft Position Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Locations Wiper Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Specifications Power Steering Fluid: Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Service and Repair Cylinder Liner: Service and Repair Cylinder Sleeve Replacement Special Tools EN-45680-880 Cylinder Liner Removal and Installation Kit Removal Procedure Caution: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. Caution: Do not damage the crankshaft connecting rod journals or reluctor ring or engine damage will occur. 1. Remove the piston and connecting rod. Refer to Piston, Connecting Rod, and Bearing Replacement (See: Piston/Service and Repair). 2. Inspect the condition of the piston. Refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection See: Service and Repair/Overhaul/28. Piston, Connecting Rod, and Bearing Cleaning and Inspection. 3. Rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore. 4. Install the EN 45680-882 cylinder bore sleeve puller (1) through the cylinder bore. Caution: Ensure that the shoe is flat against the bottom of the cylinder bore sleeve or damage to the cylinder bore sleeve puller will occur. 5. Align the shoe (1) of the EN 45680-882 cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (2). Page 2577 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) enables the fuel pump relay when the ignition switch is turned ON. The ECM will disable the fuel pump relay within 2 seconds unless the ECM detects ignition reference pulses. The ECM continues to enable the fuel pump relay as long as ignition reference pulses are detected. The ECM disables the fuel pump relay within 2 seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH 48027 - Digital Pressure Gauge * J 37287 - Fuel Line Shut-off Adapter * J 37287-FF - Fuel Line Shut-off Adapters, if equipped with an LE9 engine Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test, review the User Manual CH 48027-5 for Safety Information Instructions. 1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. Page 5583 Speaker - Right Front (UQA) Speaker - Right Front (UQ3) Page 5241 If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the Page 1241 5. Reposition the heater outlet hose clamp at the engine using the J 38185. 6. Remove the heater outlet hose from the engine. Installation Procedure 1. Install the heater outlet hose to the engine. 2. Reposition the heater outlet hose clamp at the engine using the J 38185. Page 5510 Ignition Coil 1 (LAT or LE5 or LE9) Page 6826 5. Adjust the camber setting if necessary. Rear Toe Adjustment Rear Toe Adjustment 1. Loosen the inner toe link cam bolt and nuts. 2. Rotate the cam bolt to the required toe specification settings. Refer to Wheel Alignment Measurement (See: Wheel Alignment Measurement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Maintain the toe setting while tightening the cam bolt nut. Tighten the rear suspension adjustment link lock nut to 110 Nm (81 lb ft). 4. Check the toe setting after tightening. 5. Adjust the toe setting if necessary. Application and ID Antenna Cable: Application and ID Antenna Coaxial/Connector Cable Identification Table Diagrams Air Injection Pump Relay: Diagrams Component Connector End Views Secondary Air Injection (AIR) Pump Relay (NU6) Page 1924 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the engine oil pressure switch. Tighten the switch to 22 Nm (16 lb ft). 2. Connect the engine wiring harness electrical connector (2) to the oil pressure switch. 3. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). Page 5330 Fuse Block - Underhood Top View (LE5 or LE9) Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Center Console Components 1 - Automatic Transmission Shift Lock Control Solenoid 2 - Automatic Transmission Shift Lever Position Indicator Page 10231 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 9957 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Page 4587 Control Module: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 7576 Page 4966 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module Replacement Removal Procedure Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 1. Turn the ignition switch to the OFF position. 2. Clean the electronic brake control module (EBCM) to brake pressure modulator valve (BPMV) area of any accumulated dirt and foreign material. 3. Disconnect the electrical connector from the EBCM. 4. Remove the 4 EBCM bolts (1). 5. Separate the EBCM (1) from the BPMV by carefully pulling the components apart. Page 6439 Page 79 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 10744 Washer Fluid Level Switch: Service and Repair Windshield Washer Solvent Level Indicator Replacement Removal Procedure 1. Remove the front wheelhouse panel splash shield. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 2. Disconnect the washer solvent container level sensor electrical connector. 3. Using a small flat-bladed tool, remove the washer solvent level indicator (4) from the washer solvent container (1). 4. Contain all lost windshield washer solvent into a suitable clean container. 5. Using a small flat-bladed tool, remove the level indicator seal (3) from the washer solvent container (1). Installation Procedure Page 4857 3. Using needle nose pliers carefully depress the retaining tabs on the end of the brake fluid level sensor. 4. Remove the brake fluid level sensor from the master cylinder. Installation Procedure Page 3441 15. Remove the caps from the fuel rail pipe and the EVAP purge solenoid. 16. Connect the EVAP line quick connect fitting (2) to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 17. Connect the fuel feed line quick connect fitting (3) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (See: Fuel Line Coupler/Service and Repair/Metal Collar Quick Connect Fitting Service). 18. Install the fuel feed line retainer (1) to the fuel line bracket. 19. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 21. Tighten the fuel fill cap. 22. Inspect for leaks. 1. Turn ON the ignition, with the engine OFF for 10 seconds. 2. Turn OFF the ignition for 10 seconds. 3. Turn ON the ignition, with the engine OFF. 4. Inspect for fuel leaks. Page 2163 2. Install the radiator outlet hose to the engine. 3. Reposition the radiator outlet hose clamp at the engine using the J 38185. 4. Install the radiator outlet hose to the radiator. 5. Reposition the radiator outlet hose clamp at the radiator using the J 38185. 6. Fill the coolant. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). Page 9244 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Page 6260 Electronic Brake Control Module (EBCM) (LAT) Page 1639 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 4310 Input Speed Sensor Seal Replacement Page 5671 Multiple Junction Connector: Diagrams Connector End Views By Number X100 Inline Harness Connector End Views X100 Engine Harness to Transmission Harness (ME7) Page 7893 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front Page 7868 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Page 7154 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Suspension Coil Spring Coil Spring Replacement Coil Spring Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Using a suitable jack stand, support the knuckle. 4. Remove the lower control arm to knuckle bolt and nut. Refer to Rear Axle Lower Control Arm Replacement (See: Control Arm/Service and Repair/Rear Suspension/Rear Axle Lower Control Arm Replacement). Warning To prevent personal injury and/or component damage, use the proper tools to support the lower control arm when removing the coil spring. The coil spring is under extreme pressure and can become a projectile should the spring separate from the lower control arm before all of the tension is relieved. 5. Using a adjustable jack stand, slowly lower control arm downward. 6. Remove the coil spring (1) from the lower control arm. 7. If needed, remove the rear spring upper insulator (2) or the lower spring insulator (3). Installation Procedure 1. If needed, replace the upper (2) or the lower (3) spring insulator. Page 1366 * Use TXL type wire Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Page 4252 8. Remove the transmission mount to frame bolts (1). 9. Remove the transmission mount bracket (2). Installation Procedure 1. Install the transmission mount bracket (2). Caution: Refer to Fastener Caution 2. Install the transmission bracket to frame bolts (1) and tighten to 50 Nm (37 lb ft). 3. Connect the HO2 sensor harness to the transmission mount bracket. Page 9862 Page 3066 Engine Control Module (ECM) X2 (LY7) Page 4795 Brake Rotor Assembled Lateral Runout Correction - Indexing Brake Rotor Assembled Lateral Runout Correction - Indexing Special Tools * CH-39544-KIT - Complete Torque Socket Set - 10 PCS, or equivalent * CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11, 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the CH-45101-100 - Conical Brake Rotor Washers (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. Page 10753 Wiper Switch: Diagrams Component Connector End Views Windshield Wiper/Washer Switch Wheel Alignment Measurement Alignment: Service and Repair Wheel Alignment Measurement Wheel Alignment Measurement Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead/pull is defined as follows: At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Radial Tire Lead/Pull Correction) in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections in order to ensure correct alignment readings: * Inspect for visible damage to the suspension components and replace as necessary. * Inspect the tires for the proper inflation and irregular tire wear. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label) and Tire Diagnosis - Irregular or Premature Wear (See: Wheels and Tires/Testing and Inspection/Symptom Related Diagnostic Procedures/Tire Diagnosis - Irregular or Premature Wear). * Inspect the runout of the wheels and the tires. Refer to Tire and Wheel Runout Specifications (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Specifications). * Inspect the wheel bearings for backlash and excessive play. Refer to Wheel Bearings Diagnosis (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Wheel Bearings Diagnosis). * Inspect the ball joints for looseness or wear. * Inspect the tie rod ends for looseness or wear. * Inspect the control arms and stabilizer shaft for looseness or wear. * Inspect the steering gear for looseness at the frame. Refer to Fastener Tightening Specifications (See: Steering/Specifications). * Inspect the struts/shock absorbers for wear, leaks, and any noticeable noises. Refer to Suspension Strut and Shock Absorber Testing - On Vehicle (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Suspension Strut and Shock Absorber Testing - On Vehicle). * Inspect the vehicle trim height. Refer to Trim Height Inspection (See: Suspension/Testing and Inspection/Component Tests and General Diagnostics/Trim Height Inspection). * Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. * Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Note: * Record the "Before" and "After" alignment measurements. * When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear toe adjustment first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Page 3512 Camshaft Position (CMP) Sensor - Exhaust (LAT or LE5 or LE9) Page 9625 Page 3532 Ignition Coil 2 (LY7) Page 9167 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Locations Heated Glass Element Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 3127 Page 4959 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch A/T - Water Or Coolant Contamination Information Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Locations Torque Converter Clutch Solenoid: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 5757 Fuse Block - Rear X1 Page 4516 Input Speed Sensor Seal Replacement Page 4261 1. Install the transaxle mount (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transaxle mount bolts (2) and tighten to 50 Nm (37 lb ft). 3. Install the transaxle mount through bolt (2). 4. Install the transaxle mount through bolt nut (1) and tighten to 90 Nm (66 lb ft). 5. Lower the vehicle. Transmission Rear Mount Replacement Transmission Rear Mount Replacement Removal Procedure Page 3920 Note: Fluid that is very dark or black and has a burnt odor usually indicates contamination or overheating. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal particles or other debris which may indicate transmission damage. Refer to Road Test (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/6T70/6T75 - Automatic Transmission) to verify transmission operation. Change the transmission fluid if no other conditions are found. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission (See: Testing and Inspection/Symptom Related Diagnostic Procedures/6T70/6T75 - Automatic Transmission/Engine Coolant/Water in Transmission). TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 9326 4. From the top side of the module, install the rivets which secure the drive tube retainers to the window track assembly. Install 2 rivets on each side. 5. Install the sunroof motor. Refer to Sunroof Motor/Actuator Replacement (See: Sunroof / Moonroof Motor/Service and Repair). Page 1337 Refrigerant: Service and Repair Refrigerant Recovery and Recharging Special Tools * J 43600 ACR 2000 Air Conditioning Service Center * J 45037 A/C Oil Injector Warning To prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. To remove refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers. Warning For personal protection, goggles and lint-free gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. Caution: You must replace the desiccant if the A/C refrigerant system has been open to atmosphere for more than four hours, or if the A/C refrigerant oil has been contaminated. Failure to replace the desiccant will result in damage to the A/C refrigerant system. Caution: R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. Caution: To avoid system damage use only R-134a dedicated tools when servicing the A/C system. Caution: Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. Caution: R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Specifications (See: Specifications) for the correct amount. A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Specifications ( See: Specifications). Page 6422 Starter Motor X2 (Starter to Battery) (LY7) Starter Motor X2 (Starter to Battery) (LZ4 or LZE) Starter Motor X2 (Starter to Generator) (LAT or LE5 or LE9) Starter Motor X2 (Starter to Generator) (LY7 or LZ4 or LZE) St - Ya Component Connector End Views Steering Wheel Control Switch - Left (UK3) Page 6706 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 6531 X406 Inline Harness Connector End Views X406 Decklid Jumper Harness to Body Harness Page 2253 1. Install the exhaust manifold heat shield. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the exhaust manifold heat shield bolts and tighten to 10 Nm (89 lb in). 3. Install the bank 1 sensor 1 HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (). Page 4201 Repair/Front Floor Console Replacement). 5. Disconnect the transmission range selector lever cable terminal (2) from the shift lever pin. 6. Release the transmission range selector lever cable retainer (1) and remove the transmission range selector cable from the transmission control lever base. 7. Release the transmission range selector lever cable retainer (1). Page 5606 Traction Control Switch (TCS) Transmission Control Module (TCM) (ME7) Page 4776 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Page 4377 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Boot Replacement Wheel Drive Shaft Outer Joint and Boot Replacement Special Tools * J 8059 Snap Ring Pliers * J 35910 Drive Axle Seal Clamp Pliers Removal Procedure 1. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the seal retaining clamp. Caution: Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. 2. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining clamp with a side cutter. Discard the retaining clamp. 3. Separate the halfshaft outboard seal from CV joint outer race (1) at large diameter. 4. Slide the seal (5) away from joint along halfshaft bar (4). 5. Wipe the grease from the face of the CV joint inner race (2). 6. Spread the ears on the race retaining ring (3) with J 8059. 7. Remove the CV joint assembly (1) from the halfshaft bar (4). 8. Remove the halfshaft outboard seal (5) from the halfshaft bar (4). 9. Discard the old outboard seal. Page 9608 Page 1085 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 10192 Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Locations Pedal Positioning Sensor: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Lower Left Side of the Instrument Panel Components (1 of 2) Page 9708 Page 10267 Page 3067 Page 3705 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Page 4255 Transmission Mount: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Transmission Brace Replacement Transmission Brace Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the transaxle brace bolts (1, 3). 3. Remove the transaxle brace (2). Installation Procedure Page 6313 Generator Battery Temperature Sensor 1A and Generator Battery Temperature Sensor 1B (HP7) Page 10698 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Page 2681 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Exhaust Camshaft Position Sensor Replacement - Exhaust Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (5) from the exhaust camshaft position (CMP) sensor (4). 3. Remove the CMP sensor bolt. (Intake CMP shown, exhaust CMP similar). 4. Remove the CMP sensor. Installation Procedure Page 7371 Disclaimer Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 2. Remove the engine cover, if required. 3. Remove the fuel rail service port cap. 4. Wrap a shop towel around the fuel rail service port and using a small flat bladed tool, depress (open) the fuel rail test port valve. 5. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 6. Install the fuel rail service port cap. 7. Install the engine cover, if required. 8. Tighten the fuel fill cap. Locations Headlamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) HVAC - Automatic Air Door Actuator / Motor: Service and Repair HVAC - Automatic Air Inlet Valve Actuator Replacement Air Inlet Valve Actuator Replacement Mode Valve Actuator Replacement Mode Valve Actuator Replacement Page 2697 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position (CKP) system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * CKP sensor replacement * Any engine repairs which disturb the crankshaft to CKP sensor relationship Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the CKP system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensor activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the CKP system variation learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicle's transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 5184 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to auto range to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Campaign - Airbag Readiness Light/Service Airbag Message Technical Service Bulletin # 10085D Date: 110203 Campaign - Airbag Readiness Light/Service Airbag Message CUSTOMER SATISFACTION Bulletin No.: 10085D Date: February 03, 2011 Subject: 10085D - Airbag Readiness Light/Service Airbag Message - Replace Connectors Models: 2008 Buick Enclave 2010 Chevrolet Malibu 2008 GMC Acadia 2010 Pontiac G6 2008 Saturn OUTLOOK Supercede: The Service Procedure in this bulletin has been revised. All vehicles will not require the replacement of the front seat-mounted side impact airbag connectors.Please discard all copies of bulletin 10085C, issued November 2010. Condition Certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may experience wear which could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact air bag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG System warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG System DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Correction Dealers are to replace the front seat-mounted side impact airbag connectors. Vehicles Involved Involved are certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Part Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your Page 9041 Rear Compartment Lid Inner Panel Trim Replacement Rear Compartment Lid Inner Panel Trim Replacement Page 5232 Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 2258 Converter Replacement - Right Side). Exhaust Manifold Heat Shield Replacement - Right Side Exhaust Manifold Heat Shield Replacement - Right Side Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Remove the bank 1 sensor 1 heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 (). 2. Remove the exhaust manifold heat shield bolts. 3. Remove the exhaust manifold heat shield. Installation Procedure Page 4015 Pressure Regulating Solenoid: Diagrams Component Connector End Views Pressure Control (PC) Solenoid Valve (MN5) Page 8315 Cellular Phone Microphone: Service and Repair Mobile Telephone Microphone Replacement Page 9878 Page 3277 1. Install a NEW gasket (6) to the catalytic converter. 2. Install the right (rear) catalytic converter (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the right (rear) catalytic converter bolt (5) and nuts (1) at the exhaust manifold and tighten to 45 Nm (33 lb ft). 4. Install the left (front) catalytic converter to right (rear) catalytic converter nuts (3) and tighten to 25 Nm (18 lb ft). Note: A special anti-seize compound is used on the HO2S threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 5. If reinstalling the old HO2S, coat the threads with anti-seize compound. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Exhaust System/Specifications/Fluid Type Specifications) 6. Install the lower right HO2S (2) using the J 39194-B. Tighten the sensor to 42 Nm (31 lb ft). Page 10743 Washer Fluid Level Switch: Diagrams Component Connector End Views Windshield Washer Fluid Level Switch Page 9886 Page 1013 2. Install the TFP switch assembly onto the control valve body assembly and install the bolts. Tighten the control valve body bolts to 12 Nm (9 lb ft). 3. Install the transaxle case side cover. 4. Start the engine, warm up the transaxle, and check for leaks. 5. Inspect for proper fluid level. Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 6. Reset the TAP values. Refer to Transmission Adaptive Functions See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Description and Operation. Page 6578 Fuse Block - Underhood X3 Page 1733 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 4879 Brake Hose/Line: Service and Repair Front Brake Hose Replacement Front Brake Hose Replacement Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Clean all dirt and foreign material from the brake hose ends and the brake pipe fitting. 4. Use a flare nut wrench on the brake pipe fitting (1) and a backup wrench on the brake hose (3) as shown. Page 2510 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Page 6611 Page 8194 Page 10220 For vehicles repaired under warranty use the table above. Disclaimer Page 9922 6. Release the rear lower half of the wire dress cover. 7. Release the tabs that are holding the wire dress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Turn Signal Switch Bracket Replacement Turn Signal Switch: Service and Repair Turn Signal Switch Bracket Replacement Turn Signal Switch Bracket Replacement Page 10088 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 6134 Fuses ................................................................................................................................................... ......................................................................... Usage Fuse 1 .................................................................................................................................................. .......................................... Air Conditioner Clutch Fuse 2 ................................................................... ................................................................................................................... Electronic Throttle Control Fuse 3 .................................................................................................................................................. ................................................................ Not Used Fuse 4 ................................................................. ................................................................................................ Transmission Control Module Ignition 1 Fuse 5 ............................................................................................................................................... ...................................... Mass Airflow Sensor (LY7) Page 5790 Locations Transmission Speed Sensor: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH2) Page 9116 Page 5702 X406 Inline Harness Connector End Views X406 Decklid Jumper Harness to Body Harness Page 6515 X217 Inline Harness Connector End Views X217 Body Harness to DVD Power Jumper Harness (SPO Accessory) Locations Battery Control Module: Locations Luggage Compartment/Rear of Vehicle Component Views Lower Front of the Rear Compartment Components (HP7) 1 - Generator Battery 1 2 - Generator Battery Temperature Sensor 1A 3 - Generator Battery Temperature Sensor 1B 4 - Generator Battery 2 5 - Generator Battery Temperature Sensor 2A 6 Generator Battery Temperature Sensor 2B 7 - Generator Battery 3 8 - Generator Battery Temperature Sensor 3A 9 - Generator Battery Temperature Sensor 3B 10 - Generator Battery Vent Fan 11 - Battery Current Sensor 12 - Main Contactor Relay 13 - Battery Disconnect Switch 14 Generator Battery Disconnect Control Module Page 8254 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 9189 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. Page 3805 13 - Front Differential Transfer Driven Gear 14 - Front Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual Valve Disassembled Views Disassembled Views Case and Associated Parts Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Page 9477 Service and Repair Map Light Bulb: Service and Repair Reading Lamp Bulb Replacement Page 2147 Radiator: Removal and Replacement Radiator Replacement Radiator Replacement Removal Procedure 1. Remove the cooling fan and shroud assembly. Refer to Cooling Fan and Shroud Replacement (See: Radiator Cooling Fan/Service and Repair). 2. Remove and discard the condenser mounting bolts. 3. Push upward on the condenser and downward on the radiator to unsnap the condenser mounting tabs from the radiator clips. 4. Remove and discard the condenser mounting nuts from the radiator. Page 5035 Battery Control Module: Diagrams Component Connector End Views Generator Battery Disconnect Control Module X1 (LAT) Generator Battery Disconnect Control Module X2 (LAT) Page 5384 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 9528 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 9694 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. Page 1039 1 - Control Valve Body Cover Bolt 2 - Control Valve Body Cover Assembly 3 - Control Valve Body Cover Gasket 4 - Control Valve Body Bolt 5 - Control Valve Body Cover Hole Seal 6 - Control Solenoid Valve Heat Sink Bolt 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Control Valve Body Filter Plate Assembly 9 - Control Valve Body Bolt 10 - Control Valve Body Bolt 11 Control Valve Body Assembly 12 - Control Valve Body Spacer Plate Assembly 13 - A/Trans Fluid Level Control Valve 14 - A/Trans Fluid Level Control Valve Gasket 15 - A/Trans Output Speed Sensor Bolt 16 - A/Trans Output Speed Sensor Assembly 17 - Manual Shaft Detent Spring Bolt 18 - Manual Shaft Detent Lever Spring Assembly 19 - A/Trans Input Speed Sensor Assembly 20 A/Trans Input Speed Sensor Assembly O-Ring Seal 21 - A/Trans Input Speed Sensor Bolt 22 - Fill Cap 23 - Fill Cap Seal 24 - Torque Converter Housing Gasket Locations Throttle Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left Side of the Instrument Panel Components (1 of 2) 1 - Brake Pedal Position (BPP) Sensor 2 - Accelerator Pedal Position (APP) Sensor 3 - Accelerator Pedal 4 - Brake Pedal Page 7524 5. Install the compressor pulley snap ring using the J 6083. 6. Place a small amount of oil on the 0.4 mm (0.016 in) air gap shim and place inside the clutch drive plate. 7. Install the compressor clutch plate to the compressor. Locations Hazard Warning Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 6224 Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust (LAT) Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust (LE5 or LE9) Camshaft Position (CMP) Actuator Solenoid Valve - Intake (LAT) Page 1495 Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Special Tools J 43625 Lift Pad Adapter Note: The use of a LOW PROFILE LIFT ARMS SYSTEM may be required to avoid unwanted contact with the vehicle's body and structure depending on lifting equipment used. Refer to the manufacture's recommendation for their applications of low profile lift arms system for their lifting equipment. Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents. Vehicle Lifting - Frame Contact Lift Front Lift Pads Specifications Spark Plug: Specifications Ignition System Specifications OnStar(R) - Availability for Hearing Impaired Communications Control Module: Technical Service Bulletins OnStar(R) - Availability for Hearing Impaired INFORMATION Bulletin No.: 06-08-46-005B Date: February 11, 2010 Subject: Availability of OnStar(R) for Hearing Impaired Models: 2007-2010 GM Passenger Cars and Light Duty Trucks (Including Saturn and Saab) Except 2007 Cadillac CTS Except 2007-2008 HUMMER H2, H2 SUT Except 2007 Pontiac Montana SV6 Except 2007-2010 Pontiac Vibe Except 2007 Saturn ION, VUE Except 2008 Saturn Astra Supercede: This bulletin is being revised to add a Note regarding 2009 Bluetooth(R)-equipped vehicles, additional models and model years. Please discard Corporate Bulletin Number 06-08-46-005A (Section 08 - Body and Accessories). Important This service bulletin is not applicable to 'GM of Canada' dealers and retailers. Note On 2009 and newer model year vehicles equipped with the Bluetooth(R) feature (option code UPF), when up-fitted with TTY capabilities, the Bluetooth(R) feature will be disabled. OnStar with Text Telephone Capability (TTY) General Motors is pleased to announce that the safety and security of OnStar is now available to our deaf, hard of hearing and speech impaired customers. The current vehicles listed above, as well as forthcoming vehicles equipped with OnStar hardware version 7.0 or higher, have the ability to utilize texting telephones. Vehicle specific TTY capability can be determined by utilizing the VIN lookup Tool. Additional information may be found by referring to www.onstar.com/tty. TTY equipment allows people who are deaf, hard of hearing or speech impaired, in-vehicle access to 911 and basic OnStar(R) services by pressing the OnStar(R) blue button or red emergency button. The keypad provides a means to communicate by allowing customers to type messages back and forth, with an OnStar(R) advisor or other party when using the OnStar(R) Hands-Free Calling feature. A TTY is required at both ends of the conversation in order to communicate. OnStar(R) Turn by Turn Navigation and Virtual Advisor are not available with the addition of TTY. The Reimbursement Program This equipment will be made available to eligible customers through GM Mobility and OnStar(R). Under this program, the customer must complete a GM Mobility application form. To take advantage of the program, vehicles must be adapted at the time of delivery for purchase / lease and a dealer claim ($1,000 Maximum per GM Mobility guidelines) with the application form submitted to GM Mobility. Saab dealers must fax documents. GM Dealers will receive electronic reimbursement directly from GM Mobility. Saab dealers will receive a check directly from OnStar(R). Additional questions or concerns should be directed to the OnStar Dealer Center. How to Order To order the dealer installed kit, contact AutoCraft Electronics or via the web at www.autocraft.com. The kit consists of an OnStar Interface Module, a Dial Pad (for making calls), OTIM wiring harness, the TTY device, installation/Tech 2(R) programming instructions and owner's guide. Warranty Information The Ultra-Tec Compact C TTY device is manufactured by an independent manufacturer and is covered by the manufacturer's warranty. It is not covered under the GM New Vehicle Limited Warranty. All other parts (OTIM, dial pad and OTIM wiring harness) are covered by the standard GM new vehicle parts and labor warranty. Replacement parts are available through AutoCraft Electronics. Contact AutoCraft Electronics or via the web. Warranty claims for the OTIM, dial pad and OTIM wiring harness should be submitted through normal warranty procedures using a sublet warranty claim with GM Labor Operation R5140. Page 8954 9. From below, push up on the clip slot mounting tab as shown and engage the clip on the front floor console accessory trim plate. Repeat this step on the opposite side. 10. Check the shifter trim plate retention. The trim plate should not lift up just using your finger tips. If the trim plate does lift up, the retaining clips are not seated. 11. Install the left and right console side extension panels. 12. Install the shift knob. Refer to Floor Shift Control Knob Replacement in SI. 13. Place the shifter into Park ("P") and turn the ignition key to the OFF position. 14. Release the parking brake. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 10767 Windshield Washer Pump: Service and Repair Windshield Washer Pump Replacement Removal Procedure 1. Remove the front wheelhouse panel splash shield. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 2. Disconnect the washer pump electrical connector. 3. Disconnect the washer pump hose (2) from the washer pump (5). 4. Using a small flat-bladed tool, remove the washer pump from the washer solvent container (1). 5. Drain the windshield washer solvent into a clean suitable container. 6. Using a small flat-bladed tool, remove the washer pump terminal seal (6) from the washer solvent container (1). Installation Procedure Page 118 Heated Seat Control Module - Passenger X2 (KA1) Page 9982 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 6639 Note DO NOT replace the sensing and diagnostic module (SDM), side sensors or air bag modules. Note Both driver and passenger seats must be repaired when this concern occurs even if only one DTC code is set. The service kit contains sufficient components to repair both seat connectors. Connector Replacement Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above includes harness and connector clips, which are not required in this installation. Replace connectors on both driver and passenger seats, and then reposition the connectors following the steps below. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Note Only use hand tools to remove the seat to floor mounting bolts. If there are any problems with bolt removal, refer to Corporate Bulletin Number 10-08-50-002. 2. Remove the driver's seat to floor mounting bolts. Loosen the seat from the front retainers and tilt it back to expose the underside of the seat. Refer to Front Seat Replacement - Bucket in SI. Page 9984 Cruise Control: Description and Operation Cruise Control Description and Operation Cruise control is a speed control system that maintains a desired vehicle speed under normal driving conditions at speeds above 40 km/h (25 mph). Steep grades may cause variations in the selected vehicle speeds. The following are the main components of the cruise control system: * The accelerator pedal * The brake pedal position (BPP) sensor * The body control module (BCM) * The cruise on/off switch * The + RES switch (equivalent to resume/accel switch) * The - SET switch (equivalent to set/coast switch) * The engine control module (ECM) * The throttle actuator control (TAC) motor * The vehicle speed sensor The body control module (BCM) monitors the signal circuit of the cruise control switches, which are located on the steering wheel. The BCM relays the cruise control switch status to the engine control module (ECM) via a serial data message. The ECM uses the status of the cruise control switch to determine when to capture and maintain the vehicle speed. The ECM monitors the vehicle speed signal circuit in order to determine the desired vehicle speed. The ECM uses the TAC motor in order to maintain the vehicle speed. Ignition voltage is supplied to the cruise control switch from the 2-ampere RUN/CRANK fuse located in the integrated BCM fuse block. The cruise control function switches are arranged in a resistive ladder design, with each cruise control function switch having a different resistance value. The BCM detects a specific voltage value that is associated with the cruise control function switch being activated. When the normally open cruise control on/off switch is turned ON, the switch closes illuminating the cruise control switch ON indicator, and the BCM sends a serial data message to the ECM indicating that the on/off switch is active. Similarly, when the normally open + RES switch or the normally open - SET switch are pressed, the switch closes and the BCM detects the predetermined voltage signal on the cruise control resume/accel and set/coast switch signal circuit. The BCM sends a serial data message to the ECM indicating that the + RES switch or the SET switch is active. The + RES switch or the - SET switch will remain inactive when the BCM has not received the predetermined voltage signal from the on/off switch. Cruise Control Engaged The cruise control system will engage and adjust vehicle speeds, based on the activation of the following cruise control switches, which are located on the steering wheel: * On/Off * + RES * - SET To engage the cruise control system, ensure that the vehicle speed is above 40.2 km/h (25 mph), turn the cruise On/Off switch ON and momentarily press the - SET switch. The ECM will engage the cruise control system and record the vehicle speed. The ECM sends a serial data message to the instrument panel cluster (IPC) in order to illuminate the Cruise Engaged indicator in the IPC. Pressing the accelerator pedal while the cruise control system is engaged, allows the driver to override the cruise control system in order to accelerate the vehicle beyond the current set vehicle speed. When the accelerator pedal is released, the vehicle will decelerate and resume the current set vehicle speed. The driver can also override the current set vehicle speed via the - SET switch and the + RES switch. When the cruise control system is engaged, pressing and holding the - SET switch will allow the vehicle to decelerate from the current set vehicle speed without deactivating the cruise control system. When the - SET switch is released, the ECM will record the vehicle speed and maintain the vehicle speed as the new set vehicle speed. When the cruise control system is engaged, momentarily pressing the - SET switch will allow the vehicle to decelerate at 1.6 km/h (1 mph) increments for each time that the - SET is momentarily pressed, with a minimum vehicle speed of 37 km/h (23 mph). Pressing and holding the + RES switch, when the cruise control system is engaged, will allow the vehicle to accelerate to a greater vehicle speed than the current set vehicle speed. When the + RES switch is released, the ECM will record the vehicle speed and maintain the vehicle speed as the new set vehicle speed. When the cruise control system is engaged, momentarily pressing the + RES switch will allow the vehicle to accelerate at 1.6 km/h (1 mph) increments for each time that the + RES switch is momentarily pressed, with the maximum acceleration total of 16 km/h (10 mph) over the current set vehicle speed. Momentarily activating the + RES switch will recall the previous vehicle speed, after the cruise control system is disengaged by pressing the brake pedal. Cruise Control Disengaged The engine control module (ECM) disengages the cruise control operation based on the signals from the following switches: Page 9581 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Page 6336 HVAC Control Module X2 (C60) Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 9923 9. Use the J 38125-12A tool to release the terminals by lifting the terminal retaining tabs on the inside of the connector. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Connector Position Assurance Locks Connector Position Assurance Locks Page 6098 Auxiliary Power Outlet: Service and Repair 120-Volt Accessory Power Receptacle Replacement 120-Volt Accessory Power Receptacle Replacement Page 9476 Page 958 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (LAT or LE5 or LY7 or LE9) Page 5248 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Adjustments Front Door Striker: Adjustments Door Lock Striker Adjustment Note: To determine if the striker adjustment is required, proceed as follows. 1. Ensure that the door is properly aligned with the door opening before proceeding with the striker adjustment. 2. Open and close the door on the striker (2). Note if the door drags on the striker causing the door to move upward or downward upon contact with the striker. Also note the closing effort to fully engage the latch. Note: When the striker bolts have been removed, the striker anchor plate (1) will slip down in the door pillar or quarter panel and the trim will need to be removed to gain access. 3. Using a soft marker, mark around the striker (2) for reference of the original position. Loosen the striker screws just enough to allow the movement of the door striker and shims if equipped. 4. Adjust the door striker up or down and inboard or outboard as required. Rear Bumper Fascia Replacement Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Replacement Rear Bumper Fascia Replacement Page 7004 Important: The rack and pinion boot (3) must not be twisted, puckered or out of shape in any way. If the rack and pinion boot (3) is not shaped properly, adjust the rack and pinion boot (3) by hand before installing the boot clamp. 5. Install the rack and pinion boot onto the gear assembly (1) until the rack and pinion boot (3) is seated in the gear assembly groove. 6. Install the boot clamp (1) on the rack and pinion boot (2) with J 22610. 7. Crimp the boot clamp (1). 8. Pinch the pliers together on the rack and pinion boot (2) in order to install the tie rod end clamp. 9. Install the tie rod end clamp (2) onto the rack and pinion boot (1). Page 4799 10. Mount a dial indicator, CH-45101 - hub and wheel runout gauge, or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 11. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 12. Compare the brake rotor assembled LRO to the following specification: * Front brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) * Rear brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) 13. If the brake rotor assembled LRO is within specifications, proceed to step 18. If the brake rotor assembled LRO exceeds the specification, refinish the rotor to ensure true parallelism. Refer to Brake Rotor Refinishing (See: Service and Repair/Procedures/Brake Rotor Refinishing). After refinishing the rotor, proceed to step 14. 14. Mount a dial indicator, CH-45101 - hub and wheel runout gauge, or equivalent, to the steering knuckle and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the outer edge of the rotor. 15. Measure and record the assembled LRO of the brake rotor. 1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero. 2. Rotate the rotor until the highest reading is displayed on the dial. 3. Mark the location of the high spot relative to the nearest wheel stud, or studs. 4. Measure and record the amount of LRO. 16. Compare the brake rotor assembled LRO to the following specification: * Front brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) * Rear brake rotor maximum allowable assembled lateral runout: 0.05 mm (0.002 in) 17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - conical brake rotor washers and the lug nuts. Brake Rotor Surface and Wear Inspection Brake Rotor Surface and Wear Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Page 4093 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Page 10018 Fuse Block - Underhood Relay Box: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 4594 Page 7763 3. Install the refrigerant pressure sensor wire harness connector. 4. Leak test the fittings using the J 39400-A. Page 1136 ‹› If the fuel pump does not operate, refer to Fuel Pump Electrical Circuit Diagnosis (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics/Fuel Pump Electrical Circuit Diagnosis). 2. Ignition OFF, all accessories OFF, install a CH 48027 - Pressure Gauge. Refer to Fuel Pressure Gauge Installation and Removal (See: Fuel Pressure Gauge Installation and Removal). 3. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. Verify the fuel pressure is between 345-414 kPa (50-60 psi) and does not decrease more than 34 kPa (5 psi) in 1 minute. Circuit/System Testing Note: * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * DO NOT start the engine. 1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool and observe the fuel pressure gauge while the fuel pump is operating. Verify the fuel pressure is between 345-414 kPa (50-60 psi). ‹› If the fuel pressure is greater than the specified range, replace the fuel pump module. ‹› If the fuel pressure is less than the specified range, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 2. Verify that the fuel pressure does not decrease more than 34 kPa (5 psi) in 1 minute. ‹› If the fuel pressure decreases more than the specified value, perform the following procedure: 1. Ignition OFF, relieve the fuel pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Install the J 37287 - Shut-off Adapter or the J 37287-FF Adapter between the fuel feed pipe and the fuel rail. 3. Open the valve on the J 37287 - Shut-off Adapter or the J 37287-FF - Adapter. 4. Ignition ON, command the fuel pump relay ON with a scan tool and bleed the air from the CH 48027 - Gauge. 5. Command the fuel pump relay ON and then OFF with a scan tool. 6. Close the valve on the J 37287 - Shut-off Adapter or the J 37287-FF Adapter. 7. Monitor the fuel pressure for 1 minute. ‹› If the fuel pressure decreases more than 34 kPa (5 psi) within the specified time, locate and replace the leaking fuel injectors. ‹› If the fuel pressure does not decrease more than 34 kPa (5 psi) within the specified time, replace the fuel pump module. 3. Relieve the fuel pressure to 69 kPa (10 psi). Verify that the fuel pressure does not decrease more than 14 kPa (2 psi) in 5 minutes. ‹› If the fuel pressure decreases more than the specified value, replace the fuel pump module. 4. Operate the vehicle within the conditions of the customer's concern while monitoring the fuel pressure with the CH 48027 - Gauge. The fuel pressure should not drop off during acceleration, cruise, or hard cornering. ‹› If the fuel pressure drops off, test, inspect, and repair the items listed below. If all items test normal, replace the fuel pump module. * Restricted fuel feed pipe * Inspect the harness connectors and the ground circuits of the fuel pump for poor connections. 5. If the fuel system tests normal, refer to Symptoms - Engine Controls (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Engine Controls). Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Fuel Line Replacement - Chassis (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Supply Line/Service and Repair) * Fuel Injector Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Injector/Service and Repair) * Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair) Page 6498 Brake Pedal Position (BPP) Sensor Page 2768 Page 4992 Lateral Accelerometer: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor Page 5455 Page 4693 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 413 Page 8570 Pedal Positioning Module: Diagrams Component Connector End Views Accessory Power Outlet - I/P Accessory Power Outlet - 110V AC (KV1) Page 1282 9. Remove the power steering gear inlet hose bolt (1) and disconnect the power steering gear inlet hose (2) and the power steering gear outlet hose (4) from the steering gear (3). 10. Remove the power steering gear outlet hose from the vehicle. 11. Extract the steering gear oil seals (1) from the steering gear using J-44586 - remover/installer (2) with the aid of a flat-bladed tool (3) for additional leverage. Installation Procedure Page 6973 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Page 408 Page 4897 10. Connect the rear brake pipe fitting (1) and tighten to 20 Nm (15 lb ft). 11. Connect the left rear brake pipe fitting (1) and tighten to 20 Nm (15 lb ft). Page 10533 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 6558 Power Distribution Module: Diagrams Component Connector End Views Accessory AC/DC Power Control Module X1 (KV1) Accessory AC/DC Power Control Module X2 (KV1) Page 4750 9. Install the new dust boot seal onto the caliper piston (2). 10. Insert the caliper piston into the caliper bore; using a spanner type wrench, rotate the piston (2) clockwise to fully seat the piston into the caliper body (1). 11. Fully seat the piston dust boot seal in the seal counterbore. 12. Install the piston dust boot seal retaining ring to the groove in the caliper seal counterbore. 13. Install the brake caliper to the vehicle. Refer to Rear Brake Caliper Replacement (See: Removal and Replacement/Rear Brake Caliper Replacement). Inspect the brake caliper for brake fluid leaks while performing the hydraulic brake system bleeding procedure after the caliper has been installed to the vehicle. If the brake caliper leaks brake fluid from the FRONT of the caliper past the piston dust boot seal, replace the caliper piston assembly. The piston integral adjustment mechanism contains a non-serviceable seal which may be allowing brake fluid to leak past it through a bleed hole near the end of the caliper piston. Page 3637 Page 2907 Testing Ground and Low Reference Circuits Testing Ground and Low Reference Circuits Because a test lamp can light with up to 200 ohm in a ground or low reference circuit they are not recommended to be used for this type of test. A low impedance test lamp can light and indicate the circuit is good when there is as much as 20-30 ohm present, while a high impedance test lamp can light with up to 200 ohm present in the circuit. This is why the Digital Multi-Meter (DMM) is used when validating a ground or low reference circuit continuity. When using the DMM there are many vehicle conditions that can affect the ground and low reference continuity testing. If these conditions are not met, a ground or low reference circuit test can fail on a good circuit. This may cause longer diagnosis time and incorrect component replacement. Any current flow through a ground or low reference circuit, while being tested, will skew the DMM continuity reading, or display a reading higher than when there is no current flowing. Performing a ground or low reference circuit continuity test, in reference to the vehicles battery negative terminal, will have the highest risk of failing a good ground or low reference circuit test than any other ground reference point. The best ground test points would be a control module housing (if the control modules housing is metal and grounded), door jamb striker (if attached to metal), under dash metal frame work, engine block, or body ground studs (other than where the negative battery cable is attached). A typical DMM ground or low reference circuit continuity reading can be as high as 100 ohm with the ignition ON, and drop to 15-25 ohm after the ignition is turned OFF. The reading will drop below 10 ohm after 30-40 seconds, then below 5 ohm after 60 seconds. Once the vehicle completely goes to sleep (generally 3-10 minutes) the reading will drop below 0.3 ohm. The following list of conditions may need to be met to ensure a valid continuity reading on a ground or low reference circuit: * Ignition OFF * Key out of the ignition switch (when not equipped with keyless entry and remote start) * Retained Accessory Power (RAP) OFF (open and close the driver door after ignition OFF) * Battery charger set at a 2 A or less charge rate * Scan tool not communicating with any vehicle control module (in some cases it may need to be disconnected from the DLC) * All entry doors closed * Headlamps OFF (auto headlamps disabled) * Any delay lighting OFF * HVAC after blow OFF * Any accessory that can work when the ignition is OFF * Wait up to 60 seconds (after all other listed conditions are met) Activating the DOOR LOCK function with a key fob can greatly reduce the time to achieve a valid ground or low reference continuity test result. Terminal Removal Terminal Removal Special Tools * EL-38125-580 - Terminal Release Tool Kit * EL-35616 - Connector Test Adapter Kit For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repair procedures. 1. Find the appropriate connector end view within the connector end view section. The connector end view has the following information: Page 3843 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Electronic Components (MH8) Page 1205 Note: Do not score or damage the transaxle case when removing the filter neck seal. 12. Using a chisel, indent the top of the filter neck seal to relax the press fit. 13. Remove the filter neck seal from the transaxle case and discard. 14. Remove all traces of the old gasket material. 15. Clean the transaxle case and oil pan gasket surfaces with solvent, and allow to air dry. Installation Procedure Caution: Use petroleum jelly when lubricating the components. Greases other than petroleum jelly will change the transaxle fluid characteristics and will cause undesirable shift conditions or filter clogging. 1. Install a new filter neck seal. A large socket can be used as an installation tool as shown. Two mallets can be used as well. Heated Oxygen Sensor Replacement - Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 1 Heated Oxygen Sensor Replacement - Sensor 1 Page 5563 Repeater Lamp - Left Front Page 8253 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 6259 Electric Power Steering (EPS) Module X3 (without NVH) Engine Coolant Crossover Pipe Replacement Coolant Line/Hose: Service and Repair Engine Coolant Crossover Pipe Replacement Engine Coolant Crossover Pipe Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Fuel Injector Sight Shield Replacement (). 2. Remove the generator. Refer to Generator Replacement (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). 3. Remove the drive belt idler pulleys. Refer to Drive Belt Idler Pulley Replacement (). 4. Remove the power steering pump. Refer to Power Steering Pump Replacement (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering Pump Replacement). 5. Reposition the radiator surge tank inlet hose clamp (1) at the surge tank inlet pipe. 6. Remove the radiator surge tank inlet hose from the inlet pipe. Position the hose out of the way. Page 3143 Intake Air Temperature Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 6388 Rear Compartment Courtesy Lamp Rear Compartment Lid Latch Page 2565 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) (LAT or LE5 or LE9) Knock Sensor (KS) 1 (LZ4 or LZE or LY7) Page 8125 Antenna Control Module: Diagrams Component Connector End Views Radio Antenna Module Page 9675 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Service and Repair Oil Change Reminder Lamp: Service and Repair ENGINE OIL LIFE SYSTEM When to Change Engine Oil This vehicle has a computer system that indicates when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change is indicated can vary considerably. For the oil life system to work properly, the system must be reset every time the oil is changed. When the system has calculated that oil life has been diminished, it indicates that an oil change is necessary. A CHANGE OIL SOON message comes on. Change the oil as soon as possible within the next 600 miles (1 000 km). It is possible that, if driving under the best conditions, the oil life system might not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. It is also important to check the oil regularly and keep it at the proper level. If the system is ever reset accidentally, the oil must be changed at 3,000 miles (5 000 km) since the last oil change. Remember to reset the oil life system whenever the oil is changed. How to Reset the Engine Oil Life System The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Whenever the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE OIL SOON message being turned on, reset the system. After changing the engine oil, reset the system: 1. Turn the ignition to ON/RUN, with the engine off. 2. Press and hold the Driver Information Center INFO and reset buttons, on the left side of the steering wheel, at the same time to enter the personalization menu. The OIL LIFE RESET message displays. 3. Press and hold the reset button until the Driver Information Center display shows ACKNOWLEDGED. 4. Turn the key to LOCK/OFF. If the CHANGE OIL SOON message comes back on when the vehicle is started, the engine oil life system has not reset. Repeat the procedure. What to Do with Used Oil Used engine oil contains certain elements that can be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Recycle it by taking it to a place that collects used oil. Page 915 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position (CKP) system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * CKP sensor replacement * Any engine repairs which disturb the crankshaft to CKP sensor relationship Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the CKP system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensor activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the CKP system variation learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicle's transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 4947 7. Inspect the seal on the master cylinder for damage and replace, if necessary. Ensure the seal is properly positioned on the body of the master cylinder. 8. Install the master cylinder and the EBCM/BPMV and bracket assembly to the vehicle. 9. Install the master cylinder nuts (1) and tighten to 25 Nm (18 lb ft). 10. Raise and support the vehicle. 11. Install the 3 BPMV bracket nuts (1) and tighten to 10 Nm (89 lb in). 12. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 13. Lower the vehicle. Page 5395 Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust (LAT) Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust (LE5 or LE9) Camshaft Position (CMP) Actuator Solenoid Valve - Intake (LAT) Page 1189 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. If equipped, install the tension stop (2) and fastener (1), then tighten to 10 Nm (89 lb in). 9. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Filters/Air Cleaner Housing/Service and Repair). Locations Power Window Switch: Locations Door Component Views Driver Door Components 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Passenger Door Components Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (without LAT or HP7) 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 6000 A/T Controls - Downshift Hesitation/Delayed Shifting PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T Controls Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Lighting - Low Beam Headlamp(s) Inoperative Headlamp Bulb: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 4782 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Page 6823 1. Reach around the tire, using the appropriate extension and socket. 2. Loosen both strut to knuckle nuts just enough to allow for movement. 3. If the strut has not been modified previously, perform the following steps before continuing with the wheel alignment: 1. Disconnect the strut from the knuckle. Refer to Strut Assembly Replacement (See: Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Strut/Strut Assembly Replacement). Page 9843 Front Door Weatherstrip: Service and Repair Front Side Door Upper Auxiliary Sealing Strip Replacement Front Side Door Upper Auxiliary Sealing Strip Replacement Service and Repair Rear Door Window Regulator: Service and Repair Rear Side Door Window Regulator Replacement Page 6486 Blower Motor Control Module (C68) Locations Hood Sensor/Switch (For Alarm): Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (2 of 2) 1 - Hood Ajar Switch (AP3) Page 1406 Page 1250 Page 7222 Page 9035 Trim Panel: Service and Repair Center Pillar Upper Garnish Molding Replacement Center Pillar Upper Garnish Molding Replacement Page 5653 Automatic Transmission Shift Lock Control Solenoid Backup Lamp - Left Page 2286 Disclaimer Page 7489 Blower Motor: Diagrams Component Connector End Views Blower Motor Page 5710 X601 Inline Harness Connector End Views X601 Right Front Door Harness to Right Front Door Trim Pad Harness Page 6963 1 - Steering Wheel Position Sensor (NVH) Page 456 * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information This product is current available from Kent Industries (1-888-YES-KENT). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 8147 Alarm Module: Service and Repair Theft Deterrent Module Replacement Service and Repair Torque Converter Clutch: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid Valve Replacement Replacement Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the TCC solenoid retainer clip (304), the TCC solenoid (335), with two O-rings (337, 338), and screen, the TCC regulated apply valve (339) and the spring (340). Installation Procedure 1. Install the spring (340), the TCC regulated apply valve (339), the TCC solenoid (335) with two O-rings (337 and 338) and screen, and the TCC solenoid retainer clip (304). Page 691 For vehicles repaired under warranty use the table above. Disclaimer Page 3732 2. Disconnect the input speed sensor electrical connector (1). 3. Remove the input speed sensor bolt (2) M6 x 23. 4. Remove the input speed sensor (3). 5. Remove the 3 input speed sensor seals (1). Installation Procedure Page 8192 Page 9687 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Emissions - EVAP Damage Prevention On Vehicle Hoist Vehicle Lifting: Technical Service Bulletins Emissions - EVAP Damage Prevention On Vehicle Hoist INFORMATION Bulletin No.: 05-06-04-004E Date: May 29, 2009 Subject: Information to Avoid Damaging EVAP Canister and Setting DTCs P0442/P0455 When Hoisting Vehicle Models: 2004-2007 Chevrolet Malibu MAXX 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn AURA .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 05-06-04-004D (Section 06 Engine). .............................................................................................................................................................. .................................................................................. A review of warranty repair orders and parts returned to GM for analysis suggests that EVAP canisters are being damaged when the vehicle is being put up on a hoist for service. Incorrect placement of the hoist pads may cause a crack/leak in the EVAP canister plastic and eventually set one or both of the following DTCs: - DTC P0442 - small EVAP leak detected - DTC P0455 - large EVAP leak detected To avoid this situation, particularly when using the type of hoist where the arms swing in and the pick up pads swivel, be sure of the placement of the pick up pads. If the pick up pads are not positioned correctly to the underbody pick up areas, this type of damage may occur. Lifting Points (2008 Chevrolet Malibu Shown, Other Vehicles Similar) Lifting Pad Body Seam - DO NOT Lift Here EVAP Canister - DO NOT Lift Here For additional information and detail, refer to Lifting and Jacking the Vehicle in SI. Page 10660 Front Door Window Glass: Service and Repair Front Side Door Window Replacement Page 3792 2. Attach the ball-sockets to the control assembly body and the shift-lock control lever. 3. Connect the electrical connector to the Shift Lock Control Solenoid. 4. Install the automatic transaxle control assembly. Page 5319 Body Control Module (BCM) X2 Page 8220 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Page 1885 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Special Tools CH-48027 - Digital Pressure Gauge For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). 1. With the vehicle on a level surface, allow adequate drain down time of 2-3 minutes and measure for a low oil level. Add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 2. Run the engine, and verify low, or no oil pressure on the vehicle gauge or light. Listen for a noisy valve train or a knocking noise. 3. Inspect for the following: * Correct oil filter with anti-drain back feature and O-ring on the cylinder block side of the filter * Oil diluted by moisture or unburned fuel mixtures * Improper oil viscosity for the expected temperature * Incorrect or malfunctioning oil pressure sender * Incorrect or malfunctioning oil pressure gauge * Plugged oil filter * Malfunctioning oil bypass valve 4. Remove the oil pressure sender or another engine block oil gallery plug. 5. Install CH-48027 adapter and oil pressure gauge and measure the engine oil pressure. 6. Compare the readings to specifications. Refer to Engine Mechanical Specifications (See: Specifications/Service Limits & General Specifications ). 7. If the engine oil pressure is below specifications, inspect the engine for one or more of the following: * Correct oil filter with anti-drain back feature and O-ring on the cylinder block side of the filter * Oil pump worn or dirty Refer to Oil Pump Disassemble (See: Service and Repair/Overhaul/38. Oil Pump Disassemble). * Oil pump-to-engine front cover bolts loose Refer to Engine Front Cover and Oil Pump Installation (See: Service and Repair/Overhaul/58. Engine Front Cover and Oil Pump Installation ). * Oil pump screen loose, plugged, or damaged * Oil pump screen O-ring seal missing or damaged * Malfunctioning oil pump pressure regulator valve * Excessive bearing clearance Refer to Crankshaft and Bearing Cleaning and Inspection (See: Service and Repair/Overhaul/26. Crankshaft and Bearing Cleaning and Inspection). * Cracked, porous or restricted oil galleries * Oil gallery plugs missing or incorrectly installed Refer to Engine Block Assemble (See: Service and Repair/Overhaul/45. Engine Block Assemble). * Broken lash adjusters Page 2771 * Evaporative emission (EVAP) system losses Should this vehicles on-board diagnostic system (ECM) detect a condition that could result in excessive emissions, the ECM turns ON the malfunction indicator lamp (MIL) and stores a DTC that is associated with the condition. Aftermarket (Add-On) Electrical And Vacuum Equipment Caution: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems. Caution: Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle. Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicles electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment. Add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include equipment not connected to the vehicle electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain condition is to eliminate all of the aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, the problem may be diagnosed in the normal manner. Electrostatic Discharge (ESD) Damage Note: In order to prevent possible electrostatic discharge damage to the engine control module (ECM), DO NOT touch the connector pins on the ECM. The electronic components that are used in the control systems are often designed to carry very low voltage. The electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 V of static electricity can cause damage to some electronic components. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore, it is important to use care when handling and testing electronic components. Emissions Control Information Label The underhood Vehicle Emissions Control Information Label contains important emission specifications and setting procedures. In the upper right corner is the exhaust emission information. This identifies the year, the manufacturing division of the engine, the displacement of the engine in liters, the class of the vehicle, and type of fuel metering system. There is also an illustrated emission components and vacuum hose schematic. This label is located in the engine compartment of every General Motors vehicle. If the label has been removed, it can be ordered from GM service parts operations (GMSPO). Underhood Inspection Note: This inspection is very important and must be done carefully and thoroughly. Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a condition without further steps. Use the following guidelines when performing an inspection: * Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects. * Inspect any hoses that are difficult to see. * Inspect all of the wires in the engine compartment for the following conditions: - Burned or chafed spots - Pinched wires - Contact with sharp edges - Contact with hot exhaust manifolds Page 8533 Central Control Module: Diagrams Component Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Page 9201 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. Page 1753 5. Remove the intake camshaft (1). Note: Keep all of the roller followers and hydraulic adjusters in order so that they can be reinstalled in their respective locations. 6. Remove the camshaft roller followers. 7. Remove the hydraulic element lash adjusters. Installation Procedure 1. Install the hydraulic element lash adjusters into their bores in the cylinder head. 2. Lubricate the hydraulic lash adjusters. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for the recommended lubricant. 3. Lubricate the valve tips. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers) for Page 6035 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Page 647 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Page 4254 Page 8167 Page 9973 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 2825 Procedures Sunroof / Moonroof Drain: Procedures Sunroof Drain Inspection and Cleaning Drain Hose Routing Note: If the headliner is wet DO NOT remove any interior trim. Do the Plugged Drain Hose test first. A drain trough encircles the sunroof window panel and water is drained off by the drain hoses located at each corner of the housing. A drain channel spans across the sunroof module at the rear of the window panel and directs water into the trough. 1. The front drain hoses are routed down the windshield pillars and out the center of the pillar between the door hinges. The front hoses are installed in a rubber grommet and retained by clips. 2. The rear drain hoses are routed through the rear pillars and out of the rocker panel. In some vehicle the drain hoses are routed out through the metal roof slots and routed to the lower wheelhouse to drain out of the vehicle. The rear hoses are installed in a rubber grommet and retained by clips. Plugged Drain Hose If a waterleak has occurred check for a plugged drain hose at each corner of drainage system. 1. Open the sunroof window. 2. To test for blockage, pour a small container of water into the module housing drain trough. Check each corner to confirm the drain hose is draining water. Warning Wear safety glasses in order to avoid eye damage. 3. Use compressed air, 241 kPa (35 psi) or less to blow out any drain hose that is plugged. 4. Test the system again. 5. If the hose remains plugged, check to see it is properly routed and does not have a kink. Refer to Sunroof Housing Front Drain Hose Replacement (See: Removal and Replacement/Sunroof Housing Front Drain Hose Replacement) or Sunroof Housing Rear Drain Hose Replacement (See: Removal and Replacement/Sunroof Housing Rear Drain Hose Replacement). 6. Remove the blockage using the following steps. 1. Push mechanics wire through the hose to remove the obstruction. 2. Use compressed air in order to blow out any remaining material. Disconnected Drain Hose Inspect the drainage system for disconnected drain hoses. Complete the following steps in order to obtain partial access to drain hoses and check for a disconnected hose. 1. Open the sunroof window panel. 2. Lower the headliner as needed. Refer to Headlining Trim Panel Replacement (See: Interior Moulding / Trim/Headliner/Service and Repair). 3. Connect any disconnected hoses. 4. Ensure that the rear drain hoses are properly routed in the metal roof slot and taped in place. Page 1306 Disclaimer Page 5639 Ambient Light Sensor (C60) Audio Amplifier X1 (UQA) Page 5640 Audio Amplifier X1 (UQ3) Page 1820 1. Position the crankshaft balancer. 2. Install a NEW crankshaft balancer bolt. 3. Use the J 38122-A to hold the crankshaft balancer in order to prevent the balancer from rotating while tightening the bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Tighten the crankshaft balancer bolt to 100 Nm (74 lb ft) plus an additional 125 degrees using the J 45059. 5. Install the drive belt. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). Page 1169 Compression Check: Testing and Inspection Engine Compression Test 1. Charge the battery if the battery is not fully charged. 2. Disable the ignition system. 3. Disable the fuel injection system. 4. Remove all spark plugs. 5. Turn the ignition to the ON position. 6. Depress the accelerator pedal to position the throttle plate wide open. 7. Start with the compression gauge at zero and crank the engine through 4 compression strokes, 4 puffs. 8. Measure the compression for each cylinder. Record the readings. 9. If a cylinder has low compression, inject approximately 15 ml (1 tablespoon) of engine oil into the combustion chamber through the spark plug hole. Measure the compression again and record the reading. 10. The minimum compression in any 1 cylinder should not be less than 70 percent of the highest cylinder. No cylinder should read less than 690 kPa (100 psi). For example, if the highest pressure in any 1 cylinder is 1 035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1 035 x 70% = 725) (150 x 70% = 105). * Normal - Compression builds up quickly and evenly to the specified compression for each cylinder. * Piston Rings Leaking - Compression is low on the first stroke. Compression builds up with the following strokes, but does not reach normal. Compression improves considerably when you add oil. * Valves Leaking - Compression is low on the first stroke. Compression usually does not build up on the following strokes. Compression does not improve much when you add oil. * If 2 adjacent cylinders have lower than normal compression, and injecting oil into the cylinders does not increase the compression, the cause may be a head gasket leaking between the cylinders. Page 8987 Front Floor Console Replacement Front Floor Console Replacement Page 1404 Fuse Block - Underhood Bottom View Page 8610 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Mobile Telephone Digital Antenna Replacement Antenna, Phone: Service and Repair Mobile Telephone Digital Antenna Replacement Mobile Telephone Digital Antenna Replacement Page 6769 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. OnStar(R) - Number Incorrect/Incorrectly Assigned Global Positioning System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 3343 2. Install the APP bolts (1) and tighten to 10 Nm (89 lb in). 3. Connect the APP sensor electrical connector. 4. Confirm that the APP sensor connector locking clip is fully secured. Page 10798 Wiper Motor: Diagrams Component Connector End Views Windshield Wiper Motor Page 6572 Fuse Block - Underhood Top View (LZ4 or LZE) Page 2883 Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Page 9196 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Page 1228 7. Remove the radiator surge tank pipe bolts (2). 8. Remove the radiator surge tank pipe from the crossover pipe. 9. Reposition the radiator inlet hose clamp at the crossover pipe. 10. Remove the radiator inlet hose from the crossover pipe. 11. Reposition the thermal bypass hose clamp at the crossover pipe. 12. Remove the thermal bypass hose from the crossover pipe. Capacity Specifications Refrigerant Oil: Capacity Specifications Abrupt Refrigerant Loss ....................................................................................................................... ...................................................... 60 ml (2.0 oz) (1) Compressor Replacement The service compressor for the LY7 engine is precharged with 150 ml (5 oz) of PAG oil. The service compressor for the LAT, LE5, LZ4 and LZE engines are precharged with 74 ml (2.5 oz) of PAG oil. Condenser Replacement ..................................................................................................................... ........................................................ 30 ml (1.0 oz) (2) Evaporator Replacement ............................... ............................................................................................................................................. 45 ml (1.5 oz) (2) Total System PAG Oil Capacity ............................................................................................... ..................................................................... 150 ml (5.0 oz) 1)Abrupt refrigerant loss due to large leak, hose rupture, collision, or pressure relief valve opening. Conditions that allow the refrigerant to seep or bleed off over time do not cause this oil loss. Upon replacement of a component that caused a large refrigerant loss, also add the required amount of oil for the particular component. (2)If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 8066 Seat Belt Buckle Switch: Diagrams Component Connector End Views Seat Belt Switch - Driver Seat Belt Switch - Passenger Page 6322 Heated Oxygen Sensor (HO2S) 2 (LAT or LE5 or LE9) Page 10809 Page 1207 Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic Procedures/4T45-E Automatic Transmission/Transmission Fluid Level and Condition Check). Page 8541 Communications Control Module: Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 4754 Brake Pad: Testing and Inspection Brake Pad Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are removed from the vehicle. 2. If replacement is necessary, always replace disc brake pads in axle sets. 3. Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally occurs at the trailing edge of the disc brake pads. 4. Inspect the thickness of the disc brake pads (3) in order to ensure that they have not worn prematurely. The disc brake pad wear should be approximately even per axle set. 5. Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake pad wear reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor (2). The wear indicator will then produce an audible, high-pitched warning noise during wheel rotation. 6. Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 in) of the mounting plates. 7. Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure the gap between the surfaces. If more than 0.13 mm (0.005 in) gap exists midway between the length of the disc brake pads, replace the disc brake pads. 8. Verify that any disc brake pad shims that may be required are in place and not damaged or excessively corroded. Replace any missing or damaged shims in order to preserve proper disc brake performance. 9. Replace the disc brake pads if any have separated from the mounting plates. 10. Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause noise or otherwise impair disc brake performance. Page 1445 Fuse Block - Underhood Top View (LY7) Page 802 Page 6805 Alignment: Description and Operation Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Page 6049 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to push the TPA until it bottoms out. 4. Use the J 38125-28 tool to release the terminals by inserting the tool into the terminal cavity as shown in the graphic. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 5. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Terminal Replacement Procedure Page 5548 Mode Actuator Page 6995 Second Design - Black Painted (DO NOT Lube) Hydraulic Assist Power Steering First Design - Bare Steel Tube (Lube OK) Second Design - Black Painted (DO NOT Lube) In the unlikely event that the source of the noise is identified as a second design shaft with black painted tube, it must be replaced. Correction 1 (Only for First Design - DO NOT USE FOR 2ND DESIGN) Lubricate the intermediate shaft with steering column shaft lubrication kit, P/N 26098237. 1. From inside the vehicle, remove the instrument panel insulator panel - left side panel to gain access to the intermediate shaft. 2. Remove the intermediate shaft to steering column attachment bolt. 3. Remove the intermediate shaft from the steering column. 4. Extend the intermediate shaft all the way. Using the intermediate shaft grease kit, P/N 26098237, inject the grease into the gap between the inner shaft and the outer shaft as you are collapsing the shaft. This will draw the grease into the shaft. 5. Cycle the shaft up and down several times to distribute the grease. Important Remove original thread locker material from the bolt and apply Loctite(R) 242 (or equivalent) to the threads of the bolt and reinstall intermediate shaft bolt. 6. Install the intermediate shaft to the column. Tighten - For electronic power steering, tighten the bolt to 49 Nm (36 lb ft). - For hydraulic power steering, tighten the bolt to 62 Nm (46 lb ft). Page 4735 4. Ensure the brake pad hardware mating surfaces (1) are clean. 5. Install the brake pad retainers (2) to the brake caliper bracket. 6. Install the brake pad retainers to the disc brake caliper bracket. 7. Install the brake pads to the brake caliper bracket. 8. Install the brake caliper to the mounting bracket. 9. Apply a thin coat of high temperature silicone lube to the brake caliper guide pins. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 10. Install the brake caliper guide pin bolts and tighten to 35 Nm (26 lb ft). 11. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 12. Lower the vehicle. 13. Fill the master cylinder to the proper level. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Rear Brake Caliper Hardware Replacement Rear Brake Caliper Hardware Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Caution: When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 in) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism. 4. Using a C-clamp installed to the center of the outer brake pad and the back of the caliper, slowly compress the caliper piston into its bore just enough to remove the caliper from the mounting bracket. Do not exceed 1 mm (0.039 in) of caliper piston travel. Page 1961 6. Install the EN-43649-10 - adaptor set (1) to the front and rear of the cylinder head. 7. Install the cross bars and locks (2) of the EN-43649 - compressor to the valve spring compressor adaptors. 8. Remove the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 9. Install an air hose adapter into the spark plug hole. 10. Attach an air hose to the adapter and pressurize the cylinder to 690 kPa (100 psi). 11. Compress the valve spring using the valve spring compressor (3). 12. Remove the valve spring keepers (1). 13. Remove the valve spring (3) and retainer (2). Page 5429 Electric Power Steering (EPS) Module X2 (without NVH) Page 5570 Seat Belt Switch - Driver Seat Belt Switch - Passenger Page 5443 Engine Control Module (ECM) X1 (LZ4 or LZE) Page 262 Disclaimer Page 6202 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Body - Vehicle Glass Distortion Information Back Window Glass: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 5198 The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors) * Delphi Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors) * FCI Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors) * Yazaki Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy Page 1186 Front Seat Tilt Adjuster Actuator Replacement Power Seat Motor: Service and Repair Front Seat Tilt Adjuster Actuator Replacement Front Seat Tilt Adjuster Actuator Replacement Page 2795 Page 5170 Page 6278 Page 10292 Page 8206 Page 10688 Disclaimer Page 772 Battery Current Sensor: Service and Repair Battery Current Sensor Replacement Removal Procedure 1. Remove the negative battery cable. Refer to Battery Negative Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). 2. Ensure that the location measurement of the battery current sensor was recorded for reference during installation. 3. Squeeze the ground ends of the negative battery cable together and remove the sensor (1) from the cable. Installation Procedure Important: Ensure the battery current sensor is installed in the correct direction and location on the negative battery cable. 1. Install the battery current sensor (1) by passing the ground ends of the negative battery cable through the sensor. Page 3365 Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Page 3052 Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 2049 1. Install a NEW air filter assembly. 2. Close the air cleaner cover. 3. Engage the air cleaner cover latches (1). 4. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 5. Install the air cleaner outlet duct to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Tighten the air cleaner outlet duct clamp at the air cleaner assembly to 4 Nm (35 lb in). Page 9215 1 - Outside Rearview Mirror - Passenger 2 - Door Frame 3 - Door Latch - Passenger 4 - Inflatable Restraint Side Impact Sensor (SIS) - Right 5 - Window Switch - Passenger 6 - Speaker - Right Front 7 - Window Motor - Passenger 8 - Door Lock Switch - Passenger 9 - Courtesy Lamp - Right Front Door Page 3002 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure Important: If replacing the steering wheel position sensor, the new sensor MUST come with a locating pin installed. If a locating pin is not installed, return and reorder a new steering wheel position sensor. Do not apply force to the steering wheel position sensor in a sideways direction. When reusing the steering wheel position sensor you must install a locating pin before removing it from the steering column. If the steering wheel position sensor loses its correct position it must be discarded. The locating pin diameter must be in the range of 1.0-2.0 mm. 1. Set the front wheels in the straight-ahead position and install anti-rotation pin J 42640 in the steering column lower access hole. 2. Disconnect the intermediate steering shaft from the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 3. Disconnect any electrical connectors as needed. 4. Remove the steering wheel position sensor. Assembly Procedure Page 2847 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Page 5006 Traction Control Switch: Diagrams Component Connector End Views Traction Control Switch (TCS) Page 174 4T45 - E Automatic Transmission Transmission Mount: Service and Repair 4T45 - E Automatic Transmission Transmission Mount Replacement - Left Side Transmission Mount Replacement - Left Side Removal Procedure 1. Raise and support the vehicle. 2. Remove the left front tire and wheel. 3. Remove the left splash shield. 4. Using a suitable floor jack and block of wood, support the powertrain. 5. Remove the transaxle mount lower nuts from the frame. Service and Repair Sunroof / Moonroof Cable: Service and Repair Sunroof Cable Drive Tube Replacement Removal Procedure 1. Remove the sunroof module from the vehicle. Refer to Sunroof Frame Replacement (See: Sunroof / Moonroof Frame/Service and Repair). 2. Remove the sunroof motor. Refer to Sunroof Motor/Actuator Replacement (See: Sunroof / Moonroof Motor/Service and Repair). Page 2364 Engine Control Module (ECM) X3 (LY7) Page 10432 Page 475 Locations Intake Air Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 8296 Page 2914 Information Bus: Description and Operation Data Link Communications Description and Operation Circuit Description The communication among control modules is performed through the GMLAN high speed serial data circuit and the GMLAN low speed serial data circuit. The modules that need real time communication are attached to the high speed GMLAN network. The body control module (BCM) is the gateway between the networks. The purpose of the gateway is to translate serial data messages between the GMLAN high speed buss and the GMLAN low speed buss. The gateway will interact with each network according to that network's transmission protocol. Refer to Body Control System Description and Operation (See: Body and Frame/Body Control Systems/Description and Operation) for more information about the gateway. GMLAN High Speed Circuit Description Important: A loss of serial data DTC does not represent a failure of the module that the code is set in. The data link connector (DLC) allows a scan tool to communicate with the high speed GMLAN serial data circuit. The serial data is transmitted on two twisted wires that allow speed up to 500 Kb/s. The twisted pair is terminated with two 120 ohms resistors, one is internal to the powertrain control module (PCM) or engine control module (ECM) depending on regular production option (RPO) and the other is internal to the body control module (BCM). The BCM is considered the DLC termination point of the link and the engine management controller is the other end of the link. The resistors are used to reduce noise on the High Speed GMLAN buss during normal vehicle operation. The high speed GMLAN is a differential bus. The high speed GMLAN serial data bus (+) and high speed GMLAN serial data (-) are driven to opposite extremes from a rest or idle level. The idle level, which is approximately 2.5 volts, is considered recessive transmitted data and is interpreted as a logic 1. Driving the lines to their extremes, adds one volt to the high speed GMLAN serial data bus (+) and subtracts one volt from the high speed GMLAN serial data bus (-) wire. This dominant state is interpreted as a logic 0. GMLAN network management supports selective start up and is based on virtual networks. A virtual network is a collection of signals started in response to a vehicle event. The starting of a virtual network signifies that a particular aspect of the vehicles functionality has been requested. A virtual network is supported by virtual devices, which represents a collection of signals owned by a single physical device. So, any physical device can have one or more virtual devices. The signal supervision is the process of determining whether an expected signal is being received or not. Fail softing is the ability to substitute a signal with a default value or a default algorithm, in the absence of a valid signal. Some messages are also interpreted as a heartbeat of a virtual device. If such a signal is lost, the application will set a no communication code against the respective virtual device. This code is mapped on the Tech 2 screen as a code against the physical device. GMLAN Low Speed Circuit Description The data link connector (DLC) allows a scan tool to communicate with the low speed GMLAN serial data circuit. The serial data is transmitted over a single wire to the appropriate control modules. The transmission speed for GMLAN low speed is up to 83.33 Kb/s. Under normal vehicle operating conditions, the speed of the buss is 33.33 Kb/s. This protocol produces a simple pules train sent out over the GMLAN low speed serial data bus. When a module pulls the buss high, 5 volts, this creates a dominant logic state or 0 on the buss. When the buss is pulled low 0 volts, it is translated as a recessive logic state or 1. To wake the control modules connected to the GMLAN low speed serial data buss, a high voltage wake up pulse is sent out over the buss, the voltage level of the pulse is +10 volts. Modules connected to the GMLAN low speed buss can be part of a virtual network as described in the previous paragraph. The modules on the GMLAN low speed serial data buss are connected to the buss in a parallel configuration. Data Link Connector (DLC) The data link connector (DLC) is a standardized 16-cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: * Pin 1 GMLAN low speed communications terminal * Pin 4 Scan tool power ground terminal * Pin 5 Common signal ground terminal * Pin 6 High speed GMLAN serial data bus (+) terminal * Pin 14 High speed GMLAN serial data bus (-) terminal * Pin 16 Scan tool power, battery positive voltage terminal Serial Data Reference The scan tool communicates over the various busses on the vehicle. When a scan tool is installed on a vehicle, the scan tool will try to communicate with every module that could be optioned into the vehicle. If an option is not installed on the vehicle, the scan tool will display No Comm for that options control module. In order to avert misdiagnoses of No Communication with a specific module, refer to Data Link References (See: Testing and Inspection/Initial Inspection and Diagnostic Overview) for a list of modules, the busses they communicate with, and the RPO codes for a specific module. Page 2011 6. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 7. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt Tensioner/Service and Repair). Page 2798 Page 567 Trunk / Liftgate Switch: Diagrams Component Connector End Views Rear Compartment Lid Release Switch Page 3950 Transmission Fluid Cooler Pipe Replacement - Front Transmission Fluid Cooler Pipe Replacement - Front Transmission Fluid Cooler Pipe Replacement - Rear Transmission Fluid Cooler Pipe Replacement - Rear Page 9593 Page 3537 Ignition Coil 5 (LY7) Page 9155 Sumitomo has a unique symbol on their connector and possibly a part number. The symbol is similar to that of a diamond lying on its side, similar to that shown. The logo could appear anywhere but the most common place is at the wire side of the housing. * Tyco/AMP has many different and unique connector designs. Some may or may not have identifiable marks on them. * Yazaki has a wedge or arrow shape, similar to that shown. Bosch Connectors Bosch Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 2060 Spark Plug: Application and ID Ignition System Specifications Page 5164 Page 6707 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 6519 X307 Inline Harness Connector End Views X307 PPS Module Harness to Passenger Heated Seat Harness (KA1) Page 2618 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor (2). 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2). Installation Procedure Page 8967 7. Wipe off any excessive grease on the intermediate shaft to avoid damage from drips on the carpet. 8. Install the instrument panel insulator panel - left side. 9. Verify that the noise is no longer present. Condition 2 There may be interference between the clamp and the steering gear input shaft. The clamp is beveled and if forced down on the input shaft too hard, it may cause a loose fit with the intermediate shaft to input shaft joint. Correction 2 To correct this condition, perform the following steps: 1. Remove the intermediate shaft pinch bolt at the steering gear end. 2. Install a new bolt, GM P/N 07845238, but do not tighten the bolt at this time. 3. Pry the clamp up using a pry bar to position the bolt into the upper part of the groove as shown above. This will position the clamp off the bevel. 4. While keeping the clamp in the upper position, tighten the bolt. Tighten Tighten the bolt to 49 Nm (36 lb ft). 5. Verify that the clunk noise is no longer present. Condition 3 Important This condition ONLY applies to 2004-2007 Chevrolet Malibu/Maxx and 2005-2007 Pontiac G6. Some customers may comment on a knocking or rattling type noise from the front of the vehicle when driven at low speeds and over bumps. The noise only occurs when the steering wheel is in the straight ahead position and sounds like the noise is in the left suspension of the vehicle or directly in front of the driver. Correction 3 1. Ensure the noise is not caused by Condition # 1. 2. Determine the source of the noise. Install the chassis ears at the following locations: - sway bar link - one side at a time - upper strut mount - one side at a time - steering gear near the pinion area - base of the steering column housing - radiator surge tank 3. If the noise is coming from the upper strut mount or sway bar link, replace as necessary and retest. 4. For 2004-2006 Chevrolet and Pontiac model year vehicles, the noise may be coming from the radiator surge tank area. (The 2007 model year vehicles use a different style radiator surge tank - refer to Step 9.) 5. If the noise is coming from the radiator surge tank, release the two retaining tabs holding the radiator surge tank and reposition the tank away from the attaching bracket and isolate with closed cell foam. 6. Cut three pieces of closed cell foam, P/N P46515 (or equivalent), into 25 mm (1 in) by 102 mm (4 in) pieces. 7. Cut two pieces of closed cell foam into 25 mm (1 in) by 6 mm (1/4 in) pieces. Page 5551 Outside Rearview Mirror Switch Park Brake Switch Page 8111 1 - Seat Back Cover - Passenger 2 - Heated Seat Element - Passenger Back (KA1) 3 - Seat Back Cushion Pad - Passenger 4 - Seat Belt Switch - Passenger 5 - Seat Horizontal Motor - Passenger (1LZ) 6 - Seat Rear Vertical Motor - Passenger (1LZ) 7 - Heated Seat Control Module - Passenger (KA1) 8 - Seat Front Vertical Motor - Passenger (1LZ) 9 - Heated Seat Switch - Passenger (KA1) 10 - Seat Adjuster Switch - Passenger (1LZ) 11 - Inflatable Restraint Front Passenger Presence System (PPS) Module 12 - Seat Cushion - Passenger 13 - Heated Seat Element - Passenger Cushion (KA1) 14 - Seat Cover - Passenger Page 3688 Rear Side Door Window Inner Weatherstrip Replacement Rear Door Weatherstrip: Service and Repair Rear Side Door Window Inner Weatherstrip Replacement Rear Side Door Window Inner Weatherstrip Replacement Page 6007 Door Lock Switch Replacement - Driver Door Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Driver Door Door Lock Switch Replacement - Driver Door Page 3580 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position (CKP) system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * CKP sensor replacement * Any engine repairs which disturb the crankshaft to CKP sensor relationship Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the CKP system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensor activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the CKP system variation learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicle's transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 5324 Page 6047 5. Use the J 38125-12A tool to release the terminals by inserting the tool into the left side of the terminal release cavity as shown in the graphic. Use the tool to move the terminal release to the right with a gentle prying motion. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Kostal Connectors Kostal Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 1430 1 - Fuse Block - Rear Page 5507 HVAC Control Module X2 (C60) Page 6275 Page 5191 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Page 7509 Body - Stain/Film On Windshield Glass Perimeter Windshield: Customer Interest Body - Stain/Film On Windshield Glass Perimeter TECHNICAL Bulletin No.: 09-08-48-006 Date: September 18, 2009 Subject: Clear Stain or Film on Inside Perimeter of Windshield Glass (Clean/Polish Glass) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Condition Some customers may comment on a clear stain or film on the inside of the windshield glass. This condition appears along the outer edges of the glass along the top, bottom or A-pillar areas. Normal glass cleaning procedures will not remove the stain. Cause The assembly plant uses a clear sealer/primer on the outer edge of the windshield glass to improve adhesion to the urethane adhesive that bonds the windshield glass to the vehicle body. Excess sealer/primer may drip or flow onto the windshield and cause a stain. Once the sealer/primer dries, it may appear to have etched the glass. Correction Note A "white" type of toothpaste is recommended for this repair. Gel-type toothpaste may provide less satisfactory results. Use a small amount of toothpaste on a soft, cotton cloth to polish the stained area. It may be necessary to wrap the cloth around a paint stir stick or a similar tool to reach the lower corners of the windshield glass. After polishing the glass, clean the inside of the windshield glass with a clean, damp, cotton cloth and verify all of the stain is removed. Do not use any cleaners or solvents - use only clean warm water. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Page 9170 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 9740 Service and Repair Window Track: Service and Repair Front Side Door Window Channel Replacement Specifications Timing Chain Tensioner: Specifications Timing Chain Tensioner ...................................................................................................................... ......................................................... 75 Nm (55 lb ft) Locations Tail Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 5140 OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 5115 Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Rear Compartment Lid Weatherstrip Replacement Page 8684 5. Plug weld accordingly. 6. Clean and prepare all of the welded surfaces. 7. Install all of the related panels and components. 8. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (). 9. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems (See: Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems). 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 11. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Steering - Front End Clunk/Rattle/Knock On Bumps Strut Mount: Customer Interest Steering - Front End Clunk/Rattle/Knock On Bumps TECHNICAL Bulletin No.: 06-02-32-007G Date: April 05, 2010 Subject: Clunk, Knock or Rattle Noise From Front of Vehicle While Driving or Turning Over Bumps at Low Speeds (Diagnose Noise and Perform Outlined Repair) Models: 2004-2006 Chevrolet Malibu Maxx 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn Aura Supercede: This bulletin is being revised to update the Parts Information for the bolt. Please discard Corporate Bulletin Number 06-02-32-007F (Section 02 - Steering). Condition 1 Some customers may comment on a clunk noise heard and felt in the steering wheel while driving at slow speeds and turning. The clunk noise may appear to be directly in front of the driver. Hitting a bump while turning can produce the clunk noise. Sometimes the noise may be duplicated when the vehicle is sitting still and the steering wheel is turned 90 degrees in either direction before initially centering the steering wheel. Cause 1 The clunk noise may be caused by a slip/stick condition between the inner and outer components of the intermediate shaft. Important Revised design intermediate shafts went into production in the 2009 model year and are the only design currently available through GMSPO since approximately September 2008. Since any model year vehicle could have had a second design shaft installed, it is critical to identify it before proceeding. The revised design intermediate shafts will NOT tolerate any type of lubricant per the following instructions. Adding lube to the second design shafts will cause a clunk noise in a very short period of time. Use the following pictures to identify which design of shaft you are servicing. Electric Assist Power Steering First Design - Bare Steel Tube (Lube OK) Page 10098 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 3145 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor (2). 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2). Installation Procedure Page 1700 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the wheel bearing/hub mounting bolts (1) and tighten to 115 Nm (85 lb ft). Page 4843 4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper (5). Discard the boot seal. 5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal. 6. Remove the bleeder valve cap (6). 7. Remove the bleeder valve (7). Note: Do not use abrasives to clean the brake caliper piston. 8. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 10. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 11. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered, compressed air. 12. Inspect the caliper piston for cracks, scoring, and/or damage to the plating. Replace the caliper piston if any of these conditions exist. 13. Inspect the caliper mounting holes for cracks, scoring, pitting, rust and/or excessive corrosion. Replace the caliper assembly if any of these conditions exist. Assembly Procedure Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 8376 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Transmitter Replacement Page 796 Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If reinstalling the original sensor, or if installing a NEW sensor without a sealer, coat the threads with sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor (1) to the thermostat housing and tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator Tube Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Remove the oil level indicator. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the engine wiring harness clip (1) from the oil level indicator tube bracket (2). 5. Remove the knock sensor electrical connector lead (1) from the oil level indicator tube bracket (2). 6. Lower the vehicle. OnStar(R) - Number Incorrect/Incorrectly Assigned Global Positioning System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 5345 Fuse Block - Rear Bottom View Page 5498 Heated Seat Control Module - Passenger X2 (KA1) Page 5688 X301 Inline Harness Connector End Views X301 Body Harness to the Automatic Transmission Shift Lock Control Solenoid X303 Inline Harness Connector End Views X303 Console Jumper Harness to Console Harness Page 331 Page 9866 Page 3720 64 - Band Anchor Pin (Lo/Reverse) 65 - Oil Level Control Plug 81 - Tube Assembly Bolt/Bottom Pan Bolt 84 - Transaxle Oil Filter Seal 85 - Transaxle Oil Filter Assembly 86 - Oil Level Control Valve 87 - Transaxle Bottom Pan Gasket 88 - Transaxle Oil Pan 89 - Chip Collector Magnet 120 Chip Collector Magnet (Some Models) 126 - Side Cover Stud 130 - A/Trans Auxiliary Fluid Pump Assembly 131 - Auxiliary Trans Fluid Pump Bolts 132 - Auxiliary Pump Pipe Bolts Component Location Component Location Transmission Major Components 1 - TFP Manual Valve Position Switch Assembly 2 - Control Valve Body Assembly Page 4552 Control Solenoid Valve Assembly (MH8) Page 1012 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transaxle case side cover. 2. Remove the TFP switch assembly bolts. 3. Remove the TFP switch assembly from the control valve body assembly. The TFP switch O-rings are reusable if not damaged and should remain with the switch assembly. Installation Procedure 1. Inspect the TFP switch assembly in order to verify the condition and correct location of the pressure switch O-rings. If necessary, replace the O-rings. Caution: Refer to Fastener Caution Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 5475 Fuel Injector 6 (LY7) Fuel Injector 6 (LZ4 or LZE) Page 1858 Page 6614 Page 80 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 10204 Dimmer Switch: Diagrams Component Connector End Views I/P Dimmer Switch Page 9484 Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Page 9784 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement Specifications Fluid Pan: Specifications Valve Body Cover ................................................................................................................................ ..................................................... 12 Nm (106 lb in) Page 6339 Ignition Coil 1 (LAT or LE5 or LE9) Page 6027 The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors) * Delphi Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors) * FCI Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors) * Yazaki Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy Page 5524 Inflatable Restraint Front Passenger Presence System (PPS) Module Page 9000 Glove Compartment: Service and Repair Instrument Panel Compartment Replacement Instrument Panel Compartment Replacement Page 8268 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Page 9457 Seat Cushion: Service and Repair Rear Seat Cushion Replacement Rear Seat Cushion Replacement Page 368 Page 9969 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 4859 Note: Ensure the gasket on the outside barrel of the master cylinder is positioned properly and is free of cuts and tears. 4. Install the brake master cylinder to the booster assembly. Refer to Master Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and Replacement). Page 2064 Spark Plug: Service and Repair Spark Plug Replacement Removal Procedure Caution: This engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage. 1. Remove the ignition coil(s). Refer to Ignition Coil Replacement (See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair ). Note: Make sure that any water and/or debris is blown out of the spark plug holes prior to removing the spark plugs. 2. Remove the spark plugs using a 5/8 inch spark plug socket. Installation Procedure Page 7985 Ensure that the appropriate wire colors match up (as noted in Step 4) when the connection is made between the seat airbag harness and body harness. 10. Slide all four terminals (2) into the appropriate connector body as shown above. Install the blue terminal position assurance (TPA) devices onto the connector ends. 11. Add NyoGel 760 Lubricant (dielectric lubricant), P/N 12377900 (in Canada, use P/N 10953529) (Saturn retailers, use P/N 12345579) to the terminals on both sides of the connections. 12. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the body harness up to the back of the connector. 13. Reinstall the conduit on the seat airbag harness. 14. Repeat the above procedure on the passenger seat. Reinstall Seats 1. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 2. Reconnect the seat to body harness connector and the seat airbag connector. Reroute Harness and Secure Connector Follow the procedure below to re-route and attach the harness connector to the body harness bundle: 1. The original seat airbag connector was attached with a clip to the bottom of the seat (2) as shown above. 2. Using two wire ties, secure the seat airbag connector to the seat wire bundle as shown. Ensure that there is enough slack for full range of motion of the seat. 3. Inspect the wires through the full range of motion of the seat again as in Step 2. Ensure that the wires have been secured in an orientation that allows full seat motion with adequate clearance to the connectors and sufficient slack in the wires. 4. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 5. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Page 7633 3. Install the TXV. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the TXV screws and tighten to 7 Nm (62 lb in). 5. Install the liquid line to the TXV. 6. Install the suction line to the TXV. 7. Install the liquid line and suction line nut to the TXV and tighten to 20 Nm (15 lb ft). 8. Install the liquid line to the dash clip. Page 1676 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Page 3599 Spark Plug: Testing and Inspection Spark Plug Inspection Spark Plug Usage * Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications (See: Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling - colder plug - Pre-ignition causing spark plug and/or engine damage - hotter plug Spark Plug Inspection * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. * Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Page 6604 Fuse Block - Underhood Top View (LZ4 or LZE) Page 4847 9. Install the new dust boot seal onto the caliper piston (2). 10. Insert the caliper piston into the caliper bore; using a spanner type wrench, rotate the piston (2) clockwise to fully seat the piston into the caliper body (1). 11. Fully seat the piston dust boot seal in the seal counterbore. 12. Install the piston dust boot seal retaining ring to the groove in the caliper seal counterbore. 13. Install the brake caliper to the vehicle. Refer to Rear Brake Caliper Replacement (See: Removal and Replacement/Rear Brake Caliper Replacement). Inspect the brake caliper for brake fluid leaks while performing the hydraulic brake system bleeding procedure after the caliper has been installed to the vehicle. If the brake caliper leaks brake fluid from the FRONT of the caliper past the piston dust boot seal, replace the caliper piston assembly. The piston integral adjustment mechanism contains a non-serviceable seal which may be allowing brake fluid to leak past it through a bleed hole near the end of the caliper piston. Locations Lateral Accelerometer: Locations Passenger Compartment/Roof Component Views Roof/Headliner and Under the Center Console Components 1 - Inflatable Restraint Roof Rail Module - Right Front 2 - Inflatable Restraint Roof Rail Module Left Front 3 - Yaw and Lateral Accelerometer Sensor 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Page 7666 16. Remove the liquid line and compressor hose from the condenser. 17. Remove the liquid line from the rail clip. 18. Lower the vehicle. Page 6250 Digital Video Disc (DVD) Display - Passenger Seat Headrest X2 (SPO Accessory) (UJ5) Page 8282 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Service and Repair Extension Housing: Service and Repair Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the transmission control valve body cover. 2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3). 5. Remove the 3 control valve body bolts (1) M5 x 40.5. 6. Remove the 12 control valve body bolts (2) M6 x 97. 7. Remove the control solenoid valve assembly (3) with transmission control module. Page 5341 Fuse Block - Underhood X5 (Battery Positive Cable) (without NVH) Fuse Block - Underhood X6 (Battery Positive Cable) Service and Repair Rear Door Limiter: Service and Repair Rear Side Door Check Link Replacement Page 4467 Page 9962 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close Page 6638 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. 2008 Model Year Buick Enclave, GMC Acadia and Saturn OUTLOOK Vehicles Only Note The seat mounted side impact airbag connection to the body harness is located at the forward edge of the seat, below the plastic trim. The connectors are yellow. The body harness wires are exposed - running forward in the vehicle, down through the carpet cutout in the floor. Engine Compartment Fuse Block - Owners Manual Fuse: Locations Engine Compartment Fuse Block - Owners Manual ENGINE COMPARTMENT FUSE BLOCK The vehicle may not be equipped with all the fuses and features listed. The engine compartment fuse block is located on the driver side of the engine compartment, near the battery. Notice: Spilling liquid on any electrical components on the vehicle may damage it. Always keep the covers on any electrical component. Page 3940 5. Pull the cooler line straight out from the quick connect fitting. Installation Procedure Important: * Do not reuse any of the existing oil lines or oil line fittings if there is excessive corrosion. * Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install new retaining rings. * Ensure the following procedures are performed when installing the new retaining rings onto the fittings. 1. Install a new retaining ring into the quick connect fitting using the following procedure: 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connect fitting. 3. Rotate the retaining ring around the fitting until the retaining ring is positioned with all three ears through the three slots on the fitting. Page 6541 X700 Inline Harness Connector End Views X700 Body Harness to Left Rear Door Harness Page 8784 Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Replacement Rear Side Door Outside Handle Replacement Page 3297 Canister Vent Valve: Service and Repair Evaporative Emission Canister Vent Solenoid Valve Replacement Removal Procedure 1. Drain the fuel tank. Refer to Fuel Tank Draining (See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Procedures). 2. Place a jackstand under the muffler assembly. 3. With the aid of an assistant, separate the muffler insulators (1) from the underbody hangers. 4. Slowly lower the muffler assembly allowing it to rest on the jackstand. 5. Disconnect the fuel tank fill evaporative emission (EVAP) pipe quick connect fitting (2) from the fuel tank fill EVAP emission pipe (1). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). Page 5259 Auxiliary Power Outlet: Description and Operation Power Outlets Description and Operation 12 Volt Power Outlet Receptacle Description and Operation The 12 V accessory power receptacles are supplied B+ all the time. 110 Volt Power Outlet Receptacle System Description The alternating current (AC) accessory power outlet system consists of the accessory DC/AC power inverter module and the accessory power receptacle - 110 V AC. The accessory DC/AC power inverter module converts 12 V direct current (DC) battery power to 110 V at 60 Hertz (Hz) AC power to operate AC powered devices. The accessory DC/AC power inverter module provides up to 150 watts of power. The accessory power receptacle - 110 V AC provides the usual connection for AC powered devices. 110 Volt Power Outlet Receptacle System Operation The accessory DC/AC power inverter module receives fuse protected battery voltage and is connected to the 12 V electrical system ground. The accessory power receptacle - 110 V AC has an internal switch, that detects when an AC powered device is plugged into the outlet. When the ignition is ON, and an AC powered device is plugged into the accessory power receptacle - 110 V AC, the normally open switch in the accessory power receptacle - 110 V AC, closes. When the accessory DC/AC power inverter module detects the voltage from the accessory power receptacle - 110 V AC switch, the inverter module begins to supply 110 V AC to the accessory power receptacle - 110 V AC after a 1.5 second delay. The accessory AC power system is protected against circuit overload and circuit shorts to ground. 110 Volt Power Outlet Receptacle Isolation Fault Protection The accessory DC/AC power inverter module contains a ground fault circuit interrupter (GFCI). GFCI monitors the 110 V circuit for a short to vehicle chassis ground. If a 110 V AC short to ground is detected, the accessory DC/AC power inverter module will turn OFF. The module remains OFF, until the AC powered device is unplugged from the outlet, and then plugged into the outlet after a 3 second delay. 110 Volt Power Outlet Receptacle Overload Shutdown The accessory DC/AC power inverter module will turn OFF if the current in the 110 V circuit is greater than 3.8 A for 1 second, or 2.5 A for 10 seconds. The module will turn ON again, when the AC powered device is unplugged from the outlet, and then plugged into the outlet after a 3 second delay. 110 Volt Power Outlet Receptacle Internal Shutdown The accessory DC/AC power inverter module will turn OFF if the B+ supply voltage is greater than 16.5 V or less than 11 V. The module will also turn OFF if the device temperature is greater than 85°C (185°F). The module will turn ON again, after the shutdown condition is corrected, and the AC powered device is unplugged from the outlet, and then plugged into the outlet. Page 9523 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 6123 connector housing. Refer to Repairing Connector Terminals in SI. 15. Insert the wire into the new conduit and tape the conduit end at the connector. Tape the conduit closed every 255 mm (10 in) with electrical tape. 16. Connect the fan end electrical connector into the cooling fan. 17. Fasten the new wire and conduit with tie wraps (GM P/N 12337820), as shown below. At the cooling fan end of the wire and conduit, leave adequate slack to allow for engine movement (white tie wraps are used for display purposes, use black tie wraps to match the original appearance). With RPO LY7 - Fasten the new wire and conduit to the existing harness with wire tie wraps as shown. With RPOs LZ9, LZ4 or LZE - Fasten the new wire and conduit to metal the transmission cooler lines as shown. (The lower cover has been removed to show the location of the wire tie wraps.) 18. Trim the wire and conduit to length at the underhood fuse block area. 19. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 20. Strip the wire insulation as required and install the terminal, GM P/N 15324340, on the wire. Refer to Repairing Connector Terminals in SI. 21. Reinstall the terminal into A2 on the junction block. Reinstall the TPA and the harness back cover. 22. Reconnect the harness to the under hood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 23. Reinstall the underhood fuse block into it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. Install the 40-amp fuse, GM P/N 15319478. 24. Reinstall the battery. Refer to Battery Replacement in SI. 25. Reinstall the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 26. Reinstall the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 27. Confirm the high speed cooling fan operation using the Tech 2(R). Parts Information Audio System - Noise When Using OnStar(R) Electronic Noise Suppressor: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 6059 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Page 1351 * Rear Brake Caliper Overhaul (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Overhaul/Rear Brake Caliper Overhaul)or Rear Brake Caliper Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Replacement) * Brake Pressure Modulator Valve Replacement (See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Hydraulic Control Assembly - Antilock Brakes/Service and Repair/Brake Pressure Modulator Valve Replacement) 4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm which may have allowed the moisture or particles to enter the hydraulic system. 5. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. 6. Pressure bleed the hydraulic brake system; begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (See: Hydraulic Brake System Bleeding). Page 4209 9. Remove the transmission range selector lever cable grommet (1) from the cowl panel. 10. Remove the transmission range selector lever cable from the vehicle. Installation Procedure 1. Install the transmission range selector lever cable to the vehicle. 2. Install the transmission range selector lever cable grommet (1) to the cowl panel. Page 8560 Disclaimer Brake Pressure Modulator Valve Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve Replacement Brake Pressure Modulator Valve Replacement Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. Removal Procedure 1. Turn the ignition switch to the OFF position. 2. Clean the brake pressure modulator valve (BPMV) pipe fitting areas of any accumulated dirt and foreign material. 3. Disconnect the electrical connector from the electronic brake control module (EBCM). 4. Place a shop towel under the BPMV to catch any brake fluid loss. 5. Disconnect the RF brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Page 3300 14. Slide the EVAP canister vent solenoid valve toward the rear of the vehicle. Installation Procedure 1. Slide the EVAP canister vent solenoid valve onto the bracket on the fuel tank. Page 4435 Shift Effort Shift effort will vary among different style transmissions and synchronizer designs. Usually the more heavy duty the transmission, the higher the shift effort because of the increased mass of the components. Shift effort can also be higher in cold weather because the fluid will be thicker. Medium duty transmissions will not shift as quickly as a Corvette transmission. To reduce shift effort, do not attempt to rush the shift - allow the synchronizers to work as designed. Shifting harder will only increase the chance of rushing past the synchronizer leading to grinding while shifting. Non-Synchronized Gears Some light duty truck transmissions in 1st gear (creeper-gear) and reverse gears in various transmissions, along with all gears in some medium duty transmissions, may be non-synchronized. This means there is not a mechanism to match input and output shaft speeds to allow for a smooth shift. This function is left up to the driver. This can be noticed if a shift into 1st or reverse is attempted while the vehicle is rolling or before the input shaft stops rotating leading to a gear grind. The grinding can be reduced by coming to a complete stop and pausing for a moment before shifting into the 1st or reverse gear. Some slight grinding can be expected. In medium duty non-synchronized transmissions, the driver must match input shaft (engine) speed to output shaft (driveshaft) speed with every shift. This can be accomplished by double clutching, or by using other methods. If the driver is not able to perform this function properly, there will be gear grinding with each improperly completed shift. Driver training may be required to correct this condition. Clutch brakes are used in medium duty non-synchronized transmissions to allow a shift into gear at a stop. The clutch brake is used to stop the input shaft from spinning, allowing a shift into gear at a stop without grinding. The clutch brake is activated by pressing the clutch pedal all the way to the floor. When the clutch brake is used, it is possible to have a blocked shift with the vehicle stationary. If this occurs, engage the clutch slightly to rotate the input gear to allow the shift. The clutch brake is intended to only be used while at a stop. Care must be taken to not activate the clutch brake while shifting between gears. This could lead to excessive grinding or a blocked or missed shift. Skip Shift Currently, the Cadillac CTS-V, Pontiac GTO, Chevrolet Corvette and Camaro SS (other models may follow) equipped with the 6-speed manual transmission have a feature referred to as a "skip-shift." This feature only allows a shift from 1st to 4th gear when the indicator lamp is illuminated on the dash. Dealers cannot disable this feature as it was established to help meet fuel economy standards. The conditions for this feature are: engine coolant at normal operating temperature, vehicle speed of 24-31 km/h (15-19 mph), 21% or less throttle being used (refer to Service Information or the Owner Manual for more details.) Disclaimer Page 3026 - Select Fuel Composition Reset (F1). - The first parameter is "Fuel Alcohol Content" displayed as a percentage. If the Fuel Alcohol Content percentage is above 25%, this is the probable cause of DTC P0172. - From this screen the "Fuel Alcohol Content" can be reset to zero by pressing the lower right Tech 2(R) button. It will then display 0% when it's reset. Finally, reprogram the PCM with the latest calibration. This will correct for the PCM alcohol calculations. Note The PCM must be reset from this screen. It does not reset to zero when the PCM is reprogrammed. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 6867 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Page 7466 Disclaimer OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 4330 4. Install a new control valve body to the spacer plate assembly (90). 5. Install the control valve body assembly onto the gasket. Hand start the control valve body assembly bolts (9, 12, 16) to hold the valve body in place. 6. Inspect the TFP switch assembly (2) in order to verify the condition and the correct location of the pressure switch O-rings. If necessary, replace the TFP switch assembly O-rings. 7. Install the TFP switch assembly onto the control valve body assembly. Page 6330 Heated Seat Switch - Passenger (KA1) Engine Splash Shield Replacement - Left Side Splash Guard: Service and Repair Engine Splash Shield Replacement - Left Side Engine Splash Shield Replacement - Left Side Page 9927 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 4979 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Removal Procedure 1. Remove the brake master cylinder mounting nuts from the booster and position the master cylinder to gain access to the brake fluid level sensor but do not disconnect the brake lines. Refer to Master Cylinder Replacement (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Removal and Replacement). 2. Disconnect the electrical connector from the brake fluid level sensor. Page 6526 X351 Inline Harness Connector End Views X351 Headliner Harness to Body Harness (UE1) X401 Inline Harness Connector End Views X401 Rear Lamp Harness to Left Tail Lamp Harness (without LTZ) Page 5598 Sunshade - Left (LTZ) Page 9902 Page 6530 X480 Inline Harness Connector End Views X480 Rear Lamp Harness to Rear Fascia Harness X495 Inline Harness Connector End Views X495 Rear Lamp Harness to License Lamp Harness Page 3419 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) enables the fuel pump relay when the ignition switch is turned ON. The ECM will disable the fuel pump relay within 2 seconds unless the ECM detects ignition reference pulses. The ECM continues to enable the fuel pump relay as long as ignition reference pulses are detected. The ECM disables the fuel pump relay within 2 seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH 48027 - Digital Pressure Gauge * J 37287 - Fuel Line Shut-off Adapter * J 37287-FF - Fuel Line Shut-off Adapters, if equipped with an LE9 engine Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test, review the User Manual CH 48027-5 for Safety Information Instructions. 1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. Page 5557 Radio X2 Page 3398 Fuel Injector: Service and Repair Fuel Injector Replacement Removal Procedure Caution: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method. Note: If the fuel injectors are found to be leaking, the engine oil may be contaminated with fuel. 1. Remove the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (See: Fuel Rail/Service and Repair). 2. Remove the fuel injector retainer (1). 3. Remove the fuel injector (3) from the fuel rail. 4. Remove the fuel injector upper O-ring (2). 5. Remove the fuel injector lower O-ring (4). Installation Procedure Page 9935 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 2061 Spark Plug: Testing and Inspection Spark Plug Inspection Spark Plug Usage * Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications (See: Powertrain Management/Ignition System/Specifications) for the correct spark plug. * Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: - Spark plug fouling - colder plug - Pre-ignition causing spark plug and/or engine damage - hotter plug Spark Plug Inspection * Inspect the terminal post (1) for damage. - Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. * Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: - Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Air Conditioning System Seal Replacement A/C Coupler O-ring: Service and Repair Air Conditioning System Seal Replacement Air Conditioning System Seal Replacement Removal Procedure 1. Remove the seal washer from the A/C refrigerant component. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Important: DO NOT reuse sealing washer. 4. Discard the sealing washer. Installation Procedure Important: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. Important: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. Page 563 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement Page 2767 Engine Control Module (ECM) X3 (LY7) Page 1539 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 6160 Fuse Block - Underhood Top View (LY7) Page 5119 2. Install the starter motor mounting bolts and tighten to 40 Nm (30 lb ft). 3. Install the electrical connection to the battery terminal on the solenoid and tighten the battery terminal nut to 17 Nm (13 lb ft). 4. Install the electrical connections to the S terminal on the solenoid and tighten the solenoid S terminal nut to 3 Nm (27 lb in). 5. Install the flywheel inspection cover. 6. Install the flywheel inspection cover bolts and tighten to 10 Nm (89 lb in). 7. Lower vehicle. 8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Page 4591 Transmission Control Module (TCM) (MN5 with LE5 or LE9) Front Suspension Wheel Bearing: Service and Repair Front Suspension Front Wheel Bearing and Hub Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 3. Disconnect the wheel speed sensor electrical connector, if equipped. 4. Remove the wheel speed sensor electrical connector from the mounting bracket, if needed. 5. Loosen the wheel drive shaft from the wheel bearing/hub. Refer to Wheel Drive Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement). TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 3057 Engine Control Module (ECM) X1 (LY7) Page 8294 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 2817 Electrical - Intermittent MIL/DTC P2138/Reduced Power Multiple Junction Connector: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 2464 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 5610 Page 9556 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors Yazaki Connectors Special Tools J-38125 Terminal Repair Kit Page 1086 Wiper Switch: Diagrams Component Connector End Views Windshield Wiper/Washer Switch Page 10519 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement Page 2819 Page 6299 Fuel Injector 3 (LAT or LE5 or LE9) Fuel Injector 3 (LY7) Page 4389 7. Remove the spacer ring (1), spider assembly (2), spacer ring (3) (if equipped) using J 8059, and tripot boot (4). Discard the boot and rings. 8. Clean the halfshaft bar (5). Use a wire brush in order to remove any rust in the boot mounting area (grooves). 9. Inspect the needle rollers, needle bearings, and trunnion. Check the tripot housing for unusual wear, cracks, or other damage. Replace any damaged parts with the appropriate kit. Installation Procedure Note: Place a towel in the vise before inserting the halfshaft. 1. Mount the halfshaft into a vise. 2. Place the new small eared clamp (2) onto the small end of the joint seal (1). Slide the joint seal (1) and the eared clamp (2) onto the halfshaft bar. 3. Position the small end of the joint seal (1) into the joint seal groove (3) on the halfshaft bar. Page 3993 Parking Lock Cable: Adjustments 4T45-E - Automatic Transmission Park Lock Cable Adjustment 1. Place the floor shift lever in the PARK position. 2. Turn the ignition key cylinder to the LOCK position. 3. If the front floor console is in place, remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). Note: * The key must not be able to be removed from the ignition cylinder with the transmission control lever in any position other than PARK. If they key can be removed in any other position, adjustment or repair is necessary. * The shift lever must not move from park unless the key is in the ON position. If the lever can be removed from park with the key in the OFF position, adjust or repair the park lock cable. 4. While using a small screwdriver to release the adjuster lock tang, rotate the threaded cable adjuster (1) until 3 threads are showing. 5. Re-check park lock operation. If park lock does not function, fine tune the cable 1/2 turn at a time until the proper operation is achieved. Page 10171 Frequently Asked Questions Disclaimer Radiator Air Lower Deflector Replacement Air Dam: Service and Repair Radiator Air Lower Deflector Replacement Radiator Air Lower Deflector Replacement Locations Crankshaft Position Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor 4T45-E - Automatic Transmission Transmission Mode Indicator - A/T: Service and Repair 4T45-E - Automatic Transmission Automatic Transmission Control Indicator Replacement Page 9900 Air Conditioning Evaporator Thermal Expansion Valve Replacement Expansion Block/Orifice Tube: Service and Repair Air Conditioning Evaporator Thermal Expansion Valve Replacement Air Conditioning Evaporator Thermal Expansion Valve Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 2. Remove the surge tank from the surge tank bracket. 3. Remove the suction line from the dash clip. Page 8898 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Extension Replacement Air Inlet Grille Panel Extension Replacement Page 8846 13. Remove the wire or string from the hood release cable. Installation Procedure 1. Tie the wire or string to the hood release cable. 2. Install the hood primary latch release cable through the hole in the instrument panel. 3. Install the hood release cable through the instrument panel using a small flat-bladed tool until the grommet is fully seated. 4. Remove the wire or string from the hood release cable. 5. Install the hood latch release cable ball to the latch. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the hood latch fasteners and tighten to 10 Nm (89 lb in). 7. Install the upper fascia support. 8. Install the knee bolster to the instrument panel. 9. Install the hood latch release cable handle to the instrument panel. Page 3415 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 110 Page 399 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Front Passenger Presence System (PPS) Module Inflatable Restraint Sensing and Diagnostic Module (SDM) Page 9520 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. A/C - Poor Cooling Performance/Condenser Fan Fuse Blown Fuse: Customer Interest A/C - Poor Cooling Performance/Condenser Fan Fuse Blown TECHNICAL Bulletin No.: 09-01-38-005 Date: October 09, 2009 Subject: Poor A/C Performance, Cooling Fan Fuse Blown (Install Revised Fuse And Wiring) Models: 2008-2010 Chevrolet Malibu 2006-2010 Pontiac G6 2007-2010 Saturn AURA All with RPO LY7, LZ4, LZ9 or LZE V6 Engine Condition Some customers may comment on poor A/C cooling performance. Technicians may find that the cooling fan fuse is blown. Cause High cooling fan start up loads may cause the 30-amp cooling fan fuse, located in the underhood fuse block, to blow. The lack of air flow through the A/C condenser, caused by the inoperative high-speed cooling fan, may affect the condenser's ability to dissipate heat. Correction Use the following procedure to install a heavier gauge power feed wire from the underhood fuse block to the cooling fan. After the wiring update is completed, replace the 30-amp cooling fan fuse in the underhood fuse block with a 40-amp fuse. 1. Disconnect and remove the battery. Refer to Battery Replacement in SI. 2. Remove the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 3. Disconnect the underhood fuse block from it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. It is only necessary to raise the fuse block enough to access the harness connectors. Do not remove the complete assembly from the vehicle. 4. Locate the engine wiring harness junction block assembly (X1) on the back (underside) of the underhood fuse block and disconnect it from the underhood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 5. Find pin A2, Circuit 532, cooling fan motor supply voltage. Refer to Electrical Center Identification Views, Fuse Block-Underhood X1 in SI. 6. Remove the harness back cover. Remove the TPA (terminal position assurance) clip and remove connector A2 from the junction block. Cut the terminal off and tape the wire end with electrical tape. 7. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 8. Locate the electrical connector to the right cooling fan and disconnect the wiring connector from the fan. 9. Disengage pin B, wire 3 GY, circuit 532, cooling fan motor supply voltage, from the connector housing (pull to seat terminal). Cut the terminal off of the wire and remove the wire from the connector housing. 10. Tape the end of the wire with electrical tape. 11. Prepare a 1.82 m (6 ft) section of automotive grade 5.0 mm (10 GA) wire and an equal length of 6 mm (1/4 in) flexible plastic conduit, GM P/N 12051375. 12. Run the new wire through the fan wire connector housing as shown. 13. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 14. Strip the wire insulation as required and install the terminal, GM P/N 12033997, on the wire. Secure the wire and terminal into the fan wire Page 5153 Page 7369 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Page 5099 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Page 3478 1. Install the MAF/IAT sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1) and tighten to 2.5 Nm (22 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor (2). Page 4700 Wheel Speed Sensor (WSS) - Right Front Wheel Speed Sensor (WSS) - Right Rear Page 8273 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 10752 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 9051 2. Set the load floor rear compartment cover (1) down ensuring that the retaining clips (2) align to the proper locations, carefully push down securing the cover. 3. Return both rear seats backs to their proper positions. 4. Connect the 12 volt negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Page 2201 Installation Procedure 1. Position a NEW water pump gasket and the water pump to the engine front cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the water pump bolts and tighten to 25 Nm (18 lb ft). 3. Install the water pump pulley and bolts. 4. Install the drive belt. Refer to Drive Belt Replacement (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 5. Tighten the water pump pulley bolts to 25 Nm (18 lb ft). 6. Fill the cooling system. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). 7. Inspect for leaks. Page 3266 Installation Procedure 1. Install the catalytic converter (2) along with a NEW gasket to the exhaust manifold. 2. Position and join the exhaust pipe to the catalytic converter studs. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the catalytic converter to muffler nuts and tighten to 25 Nm (18 lb ft). 4. Install the catalytic converter to exhaust manifold nuts (1) and tighten to 45 Nm (33 lb ft). 5. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 2 (See: Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor Replacement - Sensor 2). Page 5618 Wheel Speed Sensor (WSS) - Right Rear Window Motor - Driver (AXG or LTZ) Page 3272 8. Install the lower right and left HO2S (1, 2) using the J 39194-B. Tighten the sensors to 42 Nm (31 lb ft). 9. Connect the front engine wiring harness electrical connector (1) to the HO2S electrical connector. 10. Install the lower left HO2S CPA retainer (3). 11. Connect the rear HO2S electrical connector to the engine wiring harness electrical connector (2). 12. Install the lower right HO2S electrical connector CPA retainer (1). 13. Remove the muffler assembly. Refer to Exhaust Muffler Replacement (See: Engine, Cooling and Exhaust/Exhaust System/Muffler/Service and Repair). Page 9596 Page 5315 Body Control Module (BCM) Top View Page 4564 Torque Converter Clutch Solenoid: Diagrams Component Connector End Views Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve (ME7 or MN5) Page 6372 Manifold Absolute Pressure (MAP) Sensor (LZ4 or LZE) Page 7531 Page 9850 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement Rear Side Door Bottom Auxiliary Sealing Strip Replacement Page 9928 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement Tools Required J 35268-A Camshaft/Front Main Seal Installer Removal Procedure 1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement (See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair). 2. Use a flat-bladed tool to remove the seal from the front cover. Installation Procedure Page 7669 Note: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur. 8. Install the right radiator air deflector. 9. Install the right radiator air deflector retainers. 10. Install the right front fender liner. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 11. Lower the vehicle. 12. Install the suction hose and liquid line to the TXV. 13. Install the suction hose and liquid line nut to the TXV and tighten to 20 Nm (15 lb ft). 14. Install the liquid line to the dash clip. 15. Install the suction hose to the dash clip. 16. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). Page 341 Engine Control Module (ECM) X2 (LY7) Page 3977 Auxiliary Fluid Pump Replacement Auxiliary Fluid Pump Replacement Page 8141 1. Install the antenna cable to the vehicle. 2. Install the rear window shelf panel. Refer to Rear Window Shelf Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Shelf Trim Panel Replacement). 3. Install the headliner. Refer to Headlining Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair ). Page 6964 Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor (NVH) Page 928 Knock Sensor: Service and Repair Knock Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (1) from the knock sensor pigtail electrical connector (6). 4. Remove the knock sensor electrical connector pigtail (6) clip from the oil level indicator tube bracket. 5. Remove the knock sensor bolt. 6. Remove the knock sensor. Installation Procedure Instrument Panel Center Compartment Replacement Glove Compartment: Service and Repair Instrument Panel Center Compartment Replacement Instrument Panel Center Compartment Replacement Page 3074 * Evaporative emission (EVAP) system losses Should this vehicles on-board diagnostic system (ECM) detect a condition that could result in excessive emissions, the ECM turns ON the malfunction indicator lamp (MIL) and stores a DTC that is associated with the condition. Aftermarket (Add-On) Electrical And Vacuum Equipment Caution: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems. Caution: Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle. Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicles electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment. Add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include equipment not connected to the vehicle electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain condition is to eliminate all of the aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, the problem may be diagnosed in the normal manner. Electrostatic Discharge (ESD) Damage Note: In order to prevent possible electrostatic discharge damage to the engine control module (ECM), DO NOT touch the connector pins on the ECM. The electronic components that are used in the control systems are often designed to carry very low voltage. The electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 V of static electricity can cause damage to some electronic components. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore, it is important to use care when handling and testing electronic components. Emissions Control Information Label The underhood Vehicle Emissions Control Information Label contains important emission specifications and setting procedures. In the upper right corner is the exhaust emission information. This identifies the year, the manufacturing division of the engine, the displacement of the engine in liters, the class of the vehicle, and type of fuel metering system. There is also an illustrated emission components and vacuum hose schematic. This label is located in the engine compartment of every General Motors vehicle. If the label has been removed, it can be ordered from GM service parts operations (GMSPO). Underhood Inspection Note: This inspection is very important and must be done carefully and thoroughly. Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a condition without further steps. Use the following guidelines when performing an inspection: * Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects. * Inspect any hoses that are difficult to see. * Inspect all of the wires in the engine compartment for the following conditions: - Burned or chafed spots - Pinched wires - Contact with sharp edges - Contact with hot exhaust manifolds Page 5483 Generator Battery Disconnect Control Module X2 (LAT) Page 3159 Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (LAT or LE5 or LE9) Manifold Absolute Pressure (MAP) Sensor (LY7) Page 2498 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Page 3797 Shift Solenoid: Specifications 6T70/6T75 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Page 6287 Page 4741 Installation Procedure Caution: This is a self-retaining fastener joint that does not require thread locking compounds. Do not attempt to clean the threads with a standard tap. If a standard tap is used, damage to the joint threads will occur. 1. Install the brake caliper mounting bracket to the steering knuckle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the brake caliper mounting bracket bolts (1) and tighten to 130 Nm (96 lb ft). 3. Apply a very thin coating of high temperature silicone brake lubricant to the pad hardware mating surfaces (1) of the caliper bracket only. 4. Clean the brake pad mating surfaces of the brake pad retainers (2). 5. Install the brake pad retainers (2) to the brake caliper bracket. Page 5425 Door Latch - Right Rear Page 1244 Heater Hose: Service and Repair Heater Outlet Hose Replacement - Connector to Engine Heater Outlet Hose Replacement - Connector to Engine Page 2348 Engine Control Module: Diagrams Component Connector End Views Engine Control Module (ECM) X1 (LAT) Page 3164 1. Lubricate the NEW MAP sensor seal with clean engine oil. 2. Install the MAP sensor (1) into the intake manifold. 3. Connect the fuel injector wiring harness electrical connector (2) to the number 3 fuel injector. 4. Install the fuel injector wiring harness clips (1) to the fuel rail tabs. Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 898 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 10117 Page 195 Page 4141 4-3 Shift Solenoid (SS) Valve (ME7 or MN5) Control Solenoid Valve Assembly (MH2) Page 2688 Page 5508 HVAC Control Module X2 (C68) Page 7620 For vehicles repaired under warranty, use the table. Disclaimer Page 1668 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Tire Pressure Monitor - TPM System Message/Service Tips Low Tire Pressure Indicator: Technical Service Bulletins Tire Pressure Monitor - TPM System Message/Service Tips # 09-03-16-002A: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information - (Apr 27, 2010) Subject: Dealership Service Consultant Procedure as Vehicle Comes into Service Drive for Tire Pressure Monitor (TPM) System Message, Light and Customer Information Models: 2006-2011 Cars and Light Duty Trucks (Including Saturn and Saab) 2006-2010 HUMMER H2, H3 ATTENTION The information found in this bulletin is to be used as a dealership service consultant procedures for customers coming into the service lane with an illuminated "low tire light" or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. Maintaining proper tire pressures is an Owner's Maintenance item and is not covered under warranty. This bulletin is being revised to add model years and update additional bulletin reference information. Please discard Corporate Bulletin Number 09-03-16-002 (Section 03 -- Suspension). Customer Concerns and Confusion with the Tire Pressure Monitoring (TPM) System The following procedure should be used by dealership service consultants when a customer comes into the service drive with a "low tire light" on or comments on a check tire pressure/low tire pressure/add air to tire or service tire monitor system message. The service consultant should perform the following steps: Procedure Turn the key to ON, without starting the engine. ^ If the low tire light comes on and stays on solid with a check tire pressure/low tire pressure/add air to tire message (on vehicles equipped with DIC), advise the customer: - The system is working properly. - Properly adjusting all tire air pressures to the recommended levels and driving the vehicle will turn the light off (refer to the Tire and Loading Information label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". ^ If the Tire Pressure Monitor (TPM) light blinks for one minute then stays on solid with a service tire monitor system message (on vehicles equipped with DIC): - A TPM system problem exists. The vehicle should be written up accordingly and sent to your service department for further DTC diagnosis and service. - If dashes (--) are displayed in only one or two of the tire pressure readouts, it is likely caused by a previous TPM system relearn that was performed incorrectly due to interference from another vehicle's TPM system during the relearn process (refer to the Important statement later in this bulletin regarding TPM relearn with a Tech 2(R)). - If dashes (--) are displayed in all four of the tire pressure readouts, there is a system problem. Follow the appropriate SI service procedures. ^ If a customer indicates the low tire light comes on for a few minutes when the vehicle is started, then goes off after driving a while, advise the customer: - The system is working properly. - Most likely, air pressure in one or more of the tires is low enough to turn the light on when tires are cold. After driving for a while, tires will heat Locations Ambient Temperature Sensor / Switch HVAC: Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (1 of 2) 1 - Inflatable Restraint Front End Sensor - Left 2 - Ambient Air Temperature Sensor 3 - Inflatable Restraint Front End Sensor - Right Page 6586 Fuse Block - Rear X1 Page 7074 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the support mounting bolts and tighten to 100 Nm (74 lb ft). 8. Remove the transmission jack from the support. 9. Install the knuckle assembly to the support. Refer to Knuckle Replacement (See: Rear Knuckle/Service and Repair/Rear Suspension). 10. Install the upper shock absorber nuts. Refer to Shock Absorber Replacement (See: Suspension Strut / Shock Absorber/Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement). 11. Install the lower control arm assembly. Refer to Rear Axle Lower Control Arm Replacement (See: Control Arm/Service and Repair/Rear Suspension/Rear Axle Lower Control Arm Replacement). 12. Install the toe links to the support. Refer to Rear Suspension Link Replacement - Toe Link (See: Rear Knuckle Alignment Link/Service and Repair). 13. Install the park brake cable retaining bolt (3), park brake cable (1), on the trailing arm assemblies (2). 14. Install the rear wheel speed sensor wiring harness to the right rear trailing arm mounting bracket. 15. Reconnect the wheel speed sensor electrical connector at the right rear trailing arm. 16. Install the rear muffler assembly. Refer to Exhaust Muffler Replacement (See: Engine, Cooling and Exhaust/Exhaust System/Muffler/Service and Repair). Page 2699 1. Lubricate the CKP sensor O-ring seal with clean engine oil. 2. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CKP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 5. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 6. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). Page 2602 Spark Plug: Application and ID Ignition System Specifications Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Page 2846 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Page 10610 1 - Outside Rearview Mirror - Passenger 2 - Door Frame 3 - Door Latch - Passenger 4 - Inflatable Restraint Side Impact Sensor (SIS) - Right 5 - Window Switch - Passenger 6 - Speaker - Right Front 7 - Window Motor - Passenger 8 - Door Lock Switch - Passenger 9 - Courtesy Lamp - Right Front Door Rear Door Components Page 1849 Disclaimer Page 7009 8. Remove the 3 transmission rear mount bolts (1). 9. Remove the 3 rear transmission mount bracket nuts. 10. Position the transmission rear mount and bracket aside. 11. Remove the power steering gear inlet hose bolt and disconnect the power steering gear inlet hose and the power steering gear outlet hose from the steering gear. Page 4034 Page 9894 Page 4004 Important: Ensure that the ignition key is in the RUN position. Do not attempt to insert the park lock cable with the key in any other position. 6. Install the cable (1) into the inhibitor housing. 7. Turn key to LOCK position. 8. Attach the park lock cable to the shift control base. Ensure the park lock cable retainer (2) is fully secured to the shift control base. 9. Install the park lock cable on the park lock lever by sliding the cable end (1) over the park lock lever pin. 10. Inspect the functional operation of the park/lock cable. Refer to Park Lock Cable Adjustment (See: Adjustments/4T45-E - Automatic Transmission). 11. Install the knee bolster. Refer to Driver Knee Bolster Panel Replacement (See: Restraint Systems/Knee Diverter/Service and Repair). 12. Install the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 13. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Page 5764 Page 6625 Page 5654 Backup Lamp - Right Battery (+) X1 Page 3418 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 adapter (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 - adapter (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 - adapter (2). 5. Remove the hose on the CH-48027-2 - adapter (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 - gauge (1) from the CH-48027-2 - adapter (2). 3. Disconnect the CH-48027-2 - adapter (2) from the CH-48027-2 - adapter (3). 4. Disconnect the CH-48027-2 adapter (3) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Install the engine cover, if required. 7. Tighten the fuel fill cap. Page 9698 same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 2794 Page 6001 Page 6353 Inflatable Restraint Front Passenger Presence System (PPS) Module Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Page 5346 Fuse Block - Rear X1 Page 395 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 4088 4. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 5. Install the shift control cable to transaxle range switch lever and verify proper operation. Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 5110 Page 2511 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (ME7 or MN5) Page 6971 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Page 9906 Page 3918 13. If the fluid was changed, reset the transmission oil life monitor if applicable. Fluid Condition Inspection * Inspect the fluid color. The fluid should be red in color. The fluid may also turn brown form normal use, and does not always indicate contamination. Note: Fluid that is very dark or black and has a burnt odor usually indicates contamination or overheating. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal particles or other debris which may indicate transmission damage. Refer to Road Test (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/6T30/6T40/6T45 - Automatic Transmission) to verify transmission operation. Change the transmission fluid if no other conditions are found. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission (See: Testing and Inspection/Symptom Related Diagnostic Procedures/6T30/6T40/6T45 - Automatic Transmission/Engine Coolant/Water in Transmission). Page 9096 Page 7448 Note: Align the right air outlet duct to the right outlet duct extension. 1. Install the right air outlet duct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the right air outlet duct screws and tighten to 2.5 Nm (22 lb in). 3. Connect the wire harness clip at the right air outlet duct. 4. Install the right hand side window defogger duct. 5. Install the right hand side window defogger duct screws and tighten to 2.5 Nm (22 lb in). 6. Install the I/P assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Instrument Panel Center Air Outlet Duct Replacement Page 6246 Digital Video Disc (DVD) Control Module X6 (SPO Accessory) (UJ5) Page 10042 General Electrical Diagnosis General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (V), current (A), and resistance (Ohms ). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Vehicle Zoning Strategy Vehicle Zoning Strategy All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Page 9064 Key: Testing and Inspection Replacing Keys 10-Minute Vehicle Key Relearn Important: This procedure will only relearn the vehicle keys. This procedure will not learn the start enable password. Do not use this procedure as a substitute for a 10-minute relearn when replacing or reprogramming a theft deterrent module (TDM) or engine control module (ECM). Doing so will result in a failure to learn the required password. This 10-minute learn procedure should be used when all vehicle keys are desired to be replaced or reprogrammed. This procedure will erase all previously learned vehicle keys from the TDM. Once the 10-minute learn procedure has been completed, any remaining vehicle keys may be programmed using the Adding Keys procedure to ensure their continued functionality. 1. Connect a scan tool to the vehicle in the pass-thru arrangement. 2. Turn ON the ignition, with the engine OFF. 3. Ensure that all power consuming devices are turned OFF on the vehicle. 4. On the Techline Terminal, select Service Programming System and follow the Techline Terminal on-screen instructions, using the Legacy Pass-Thru method. Ensure the correct programming selection is chosen based on component being replaced or programmed. For this procedure, go to the V.T.D. Vehicle Theft Deterrent Learn menu and choose the Vehicle Theft Deterrent Learn for Learning Replacement Keys selection. 5. At this point the scan tool must remain connected for the duration of the 10-minute relearn procedure. Important: ^ The scan tool may initially display 12 Minutes. The first 2 minutes allow the scan tool to initialize the appropriate control module. The remaining 10 minutes is the relearn timer. ^ On some vehicles the security indicator may be illuminated for the duration of the 10-minute relearn procedure. 6. Observe the scan tool, after approximately 10 minutes the scan tool will display "Programming Successful, Turn OFF Ignition". The vehicle is now ready to relearn the key information and/or the passwords on the next ignition switch transition from OFF to CRANK. 7. Turn OFF the ignition and wait 2 minutes. 8. With the first vehicle key, turn the ignition to the RUN position for 15 seconds, then start the vehicle. 9. With the second vehicle key, turn the ignition to the RUN position for 15 seconds, then start the vehicle. The TDM has now learned the key transponder information. 10. With a scan tool, clear any DTCs. Page 5965 Page 2403 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 9006 Locations Intake Air Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 979 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Page 3106 Camshaft Position (CMP) Sensor - Exhaust (LAT or LE5 or LE9) Page 4643 25 - Torque Converter and Support and A/Trans Fluid Pump Housing Assembly 26 - Torque Converter and Differential Housing Bolt 27 - Torque Converter Assembly 28 - Dust Cover Push Pin - Model Dependent 29 - Dust Cover Bolt - Model Dependent 30 - Dust Cover - Model Dependent 31 - Front Differential Carrier Assembly 32 - Input Shaft Thrust Bearing Assembly 33 - A/Trans Case Cover Gasket 34 - A/Trans Case Cover Assembly 35 - A/Trans Case Cover Assembly Bolt A/Trans Case Cover, 2-6 and Low Reverse Pistons 400 - A/Trans Input Speed Sensor Assembly 401 - A/Trans Input Speed Sensor Bolt 402 - ISS O-Ring Seal 403 - A/Trans Case Cover Assembly 404 - 3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring 405 - 2-6 Clutch Piston 406 - 2-6 Clutch Spring Assembly 407 - 2-6 Clutch Spring Retainer Ring 408 - Low and Reverse Clutch Piston Assembly 409 - Low and Reverse Clutch Spring 410 Low and Reverse Clutch Spring Retainer Ring Service and Repair Rear Bumper Shock Absorber: Service and Repair Rear Energy Absorber Replacement Page 2528 1. Install the MAF/IAT sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1) and tighten to 2.5 Nm (22 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor (2). 4T45-E - Automatic Transmission Shift Solenoid: Service and Repair 4T45-E - Automatic Transmission 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Description and Operation. 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to Page 28 Communications Control Module: Service and Repair Communication Interface Module Bracket Replacement Communication Interface Module Bracket Replacement Page 5868 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 2553 Page 68 Accessory Power Outlet - Center Console Page 9692 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close Page 4699 Wheel Speed Sensor: Diagrams Component Connector End Views Wheel Speed Sensor (WSS) - Left Front Wheel Speed Sensor (WSS) - Left Rear Page 5456 Engine Control Module (ECM) X3 (LAT) Page 2749 Engine Control Module: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 6286 Engine Control Module (ECM) X3 (LY7) Page 9569 If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the Page 8362 Digital Video Disc (DVD) Display - Driver Seat Headrest X1 (SPO Accessory) (UJ5) Metal Collar Quick Connect Fitting Service Fuel Line Coupler: Service and Repair Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service Special Tools EN-37088-A - Fuel Line Disconnect Tool Set For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Removal Procedure 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Remove the retainer from the quick connect fitting. Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 3. Blow dirt out of the fitting using compressed air. 4. Choose the correct tool from the EN-37088-A - set for the size of the fitting. Insert the tool into the female connector, then push inward in order to release the locking tabs. Page 2752 Engine Control Module (ECM) X1 (LE5 or LE9) Page 5181 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear fascia. Refer to Rear Bumper Fascia Replacement (See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement). 3. Remove the pressure relief valve from under vehicle, behind rear fascia. Installation Procedure 1. Install the pressure relief valve. 2. Install the rear fascia. Refer to Rear Bumper Fascia Replacement (See: Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia Replacement). Locations Intake Air Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 8701 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Center Bracket Replacement Rear Bumper Fascia Center Bracket Replacement Page 1764 Note: Ensure that the alignment mark previously on the intake camshaft actuator is still aligned properly with the timing chain. If the mark made previously on the intake camshaft actuator is not aligned properly, refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement (See: Timing Components/Timing Chain Tensioner/Service and Repair). 5. Remove the timing chain retention tool (1) from the exhaust side of the timing chain. Note: Failure to reset the tensioner will allow the tensioner to over extend. limiting the timing chain life. 6. Reset and install the timing chain tensioner. Refer to Timing Chain Tensioner Replacement (See: Timing Components/Timing Chain Tensioner/Service and Repair). 7. Install the EN-48953 - retention tool (1). 8. Install the camshaft actuator retainer bolts and tighten to 10 Nm (89 lb in). 9. Tighten the NEW camshaft actuator bolt to 30 Nm (22 lb ft) plus an additional 100 degrees using the EN-45059 - meter. Note: You must have the EN-48953 - retention tool installed to perform this procedure. Page 1942 16. Remove the 3-phase voltage cable bracket bolt (1) at the oil level indicator tube. 17. Remove the generator starter bolts. 18. Reposition and secure the generator starter out of the way. Page 352 1. Set the ECM (2) into the bottom of the bracket and push the ECM towards the battery until the ECM snaps into place and is secured by the retainers (1). 2. Connect the engine wiring harness electrical connectors (2) to the ECM. 3. Install the engine wiring harness clips (3) to the ECM bracket (4). Page 2548 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. (Intake CMP shown, exhaust CMP similar). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect engine wiring harness electrical connector (5) to the exhaust CMP sensor (4). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 10121 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 5914 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 1819 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement Special Tools * J 38122-A Harmonic Balancer Holder * J 45059 Angle Meter Removal Procedure 1. Remove the drive belt. Refer to Drive Belt Replacement (See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 2. Use J 38122-A to prevent the crankshaft from rotating while loosening the crankshaft balancer bolt. 3. Remove and discard the crankshaft balancer bolt. 4. Remove the crankshaft balancer. Installation Procedure Service and Repair Rear Bumper Reinforcement: Service and Repair Rear Bumper Impact Bar Replacement Page 829 Knock Sensor (KS) 2 (LZ4 or LZE or LY7) Page 9468 Page 3578 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LAT or LE5 or LE9) Crankshaft Position (CKP) Sensor (LY7) Page 1108 Alignment: Description and Operation Caster Description Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Toe Description Toe Description Procedures Radiator: Procedures Radiator Cleaning Warning NEVER spray water on a hot heat exchanger. The resulting steam could cause personal injury. Caution: The heat exchanger fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer. Note: Remove bugs, leaves, dirt and other debris by blowing compressed air through the engine side of the radiator. * Some conditions may require the use of warm water and a mild detergent. * Clean the A/C condenser fins. * Clean between the A/C condenser and radiator. * Clean the radiator cooling fins. * Straighten any damaged cooling fins. Page 5697 X351 Inline Harness Connector End Views X351 Headliner Harness to Body Harness (UE1) X401 Inline Harness Connector End Views X401 Rear Lamp Harness to Left Tail Lamp Harness (without LTZ) Page 389 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 4301 25 - Torque Converter and Support and A/Trans Fluid Pump Housing Assembly 26 - Torque Converter and Differential Housing Bolt 27 - Torque Converter Assembly 28 - Dust Cover Push Pin - Model Dependent 29 - Dust Cover Bolt - Model Dependent 30 - Dust Cover - Model Dependent 31 - Front Differential Carrier Assembly 32 - Input Shaft Thrust Bearing Assembly 33 - A/Trans Case Cover Gasket 34 - A/Trans Case Cover Assembly 35 - A/Trans Case Cover Assembly Bolt A/Trans Case Cover, 2-6 and Low Reverse Pistons 400 - A/Trans Input Speed Sensor Assembly 401 - A/Trans Input Speed Sensor Bolt 402 - ISS O-Ring Seal 403 - A/Trans Case Cover Assembly 404 - 3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring 405 - 2-6 Clutch Piston 406 - 2-6 Clutch Spring Assembly 407 - 2-6 Clutch Spring Retainer Ring 408 - Low and Reverse Clutch Piston Assembly 409 - Low and Reverse Clutch Spring 410 Low and Reverse Clutch Spring Retainer Ring Page 4210 3. Attach the transmission range selector lever cable retainer. 4. Install the transmission range selector lever cable to the transmission control lever base. Ensure the cable retainer (1) is fully secured to the transmission control lever base. 5. Connect the transmission range selector lever cable terminal (2) to the shift lever pin. 6. Install the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). Page 9819 Splash Guard: Service and Repair Engine Splash Shield Replacement Engine Splash Shield Replacement Page 3165 5. Connect the fuel injector wiring harness electrical connector (1) to the MAP sensor. 6. Position the EVAP canister purge tube (1) out of the way. 7. Connect the EVAP canister purge tube to the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 8. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 1025 Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 4. Remove the transaxle range switch lever nut and lever. 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. Page 247 Fuse Block - Rear X3 Page 9565 within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) System Diagnosis Idle Speed: Testing and Inspection Throttle/Idle Learn Description The engine control module (ECM) learns the idle position of the throttle plate to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned. A vehicle that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero. The idle may be unstable or a DTC may set if the learned values do not match the actual airflow. Conditions for Running the Throttle Learn Procedure * DTCs P0101, P0102, P0103, P0107, P0108, P0111, P0112, P0113, P0506, and P0507 are not set. * The engine speed is between 450-4,000 RPM. * The manifold absolute pressure (MAP) is greater than 5 kPa. * The mass air flow (MAF) is greater than 2 g/s. * The ignition 1 voltage is greater than 10 volts. Throttle Learn With Scan Tool-Reset 1. Ignition ON, engine OFF. With a scan tool, perform the Idle Learn Reset in Module Setup. 2. Start the engine, monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation parameter value should equal 0 percent and the engine should be idling at a normal idle speed. ‹› If the engine is not idling normally, proceed with the Learn portion of the diagnostic. 3. Clear the DTCs and return to the diagnostic that referred you here. Without Scan Tool-Learn Important: Do NOT perform the Without Scan Tool-Learn procedure if DTCs are set. Refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle). 1. The engine speed is between 450-4,000 RPM. 2. The manifold absolute pressure (MAP) is greater than 5 kPa. 3. The mass air flow (MAF) is greater than 2 g/s. 4. The ignition 1 voltage is greater than 10 volts. 5. Start and idle the engine in Park for 3 minutes. 6. With a scan tool, monitor desired and actual RPM. 7. The ECM will start to learn the new idle cells and Desired RPM should start to decrease. 8. Ignition OFF for 60 seconds. 9. Start and idle the engine in Park for 3 minutes. Important: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. 10. After the 3 minute run time the engine should be idling normal. ‹› If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles. 11. After the drive cycle, the engine should be idling normally. ‹› If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6. 12. Once the engine speed has returned to normal, clear DTCs. Page 9480 Locations Ambient Temperature Sensor / Switch HVAC: Locations Front of Vehicle/Engine Compartment Component Views Front of the Engine Compartment Components (1 of 2) 1 - Inflatable Restraint Front End Sensor - Left 2 - Ambient Air Temperature Sensor 3 - Inflatable Restraint Front End Sensor - Right Page 6672 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer A/T Controls - Downshift Hesitation/Delayed Shifting Control Module: All Technical Service Bulletins A/T Controls - Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 3163 5. Remove the fuel injector wiring harness clips (1) from the fuel rail tabs. 6. Disconnect the fuel injector wiring harness electrical connector (2) from the number 3 fuel injector. 7. Squeeze tabs and slide the MAP sensor (1) upward. Installation Procedure Wheel Drive Shaft Inner Joint and Boot Replacement Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Boot Replacement Wheel Drive Shaft Inner Joint and Boot Replacement Special Tools * J 8059 Snap Ring Pliers (Parallel Jaw) * J 35910 Drive Axle Seal Clamp Pliers Removal Procedure Caution: Do not cut through the wheel drive shaft inboard or outboard boot during service. Cutting through the boot may damage the sealing surface of the housing and the tripot or the constant velocity joint bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. 1. If equipped with a small swage ring, use a hand grinder to cut through the swage ring, taking care not to damage the halfshaft bar, in order to remove the swage ring. Otherwise, remove the small seal retaining clamp with a side cutter. Discard the retaining clamp. 2. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal retaining clamp. 3. Separate the inboard seal from the trilobal tripot bushing (3) at the large diameter. 4. Slide the seal away from the joint along the halfshaft bar. Service and Repair Sunroof / Moonroof Interior Trim Panel: Service and Repair Sunroof Opening Trim Finish Lace Replacement Removal Procedure 1. Beginning at the joint on the left side of the sunroof opening, pull the sunroof finishing lace from the sunroof window track assembly. 2. Remove the sunroof finishing lace from the track assembly. Installation Procedure 1. Position the end of the sunroof finishing lace at the center of the left side of the sunroof opening. 2. Push the finishing lace (2) onto the track assembly flange (1) until fully seated around the sunroof opening. Page 9963 within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) Page 4176 Removal Procedure 1. Set the park brake and chock the wheels. 2. Remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 3. Disconnect the transmission range selector lever cable terminal (2) from the shift lever pin (3). 4. Release the transmission range selector lever cable retainer (1) and remove the transmission range selector cable from the transmission control lever base (4). 5. Remove the park lock cable end (1) from the park lock lever by sliding the cable end reward off the park lock lever pin 6. Release the park lock cable retainer (2) from the shift control base. Page 7339 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement Special Tools J 45405 Pipe Flaring Tool Kit Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Warning Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Note: When servicing the brake pipes, note the following: * If sectioning the brake pipe, use replacement pipe of the same type and outside diameter. * Use fittings of the appropriate size and type. * Only create flares of the same type or design as originally equipped on the vehicle. 1. Inspect the area of brake pipe to be repaired or replaced. 2. Release the brake pipe to be replaced from the retainers, as required. 3. Select an appropriate location to section the brake pipe, if necessary. * Allow adequate clearance in order to maneuver the J 45405. * Avoid sectioning the brake pipe at bends or mounting points. 4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends. 5. Add to the measurement taken the appropriate additional length required for each flare to be created. * 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe * 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe * 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe Page 10087 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 5098 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Page 6704 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 10291 Page 1618 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 4842 Brake Caliper: Overhaul Front Brake Caliper Overhaul Front Brake Caliper Overhaul Disassembly Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Remove the brake caliper from the vehicle. Refer to Front Brake Caliper Replacement (See: Removal and Replacement/Front Brake Caliper Replacement). Warning Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Caution: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Remove the retaining ring that secures the dust boot to the caliper housing. Locations Pedal Positioning Motor: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 6042 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wire dress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Body - Marks/Stains on Windshield When Wet Windshield: Customer Interest Body - Marks/Stains on Windshield When Wet TECHNICAL Bulletin No.: 09-08-48-002A Date: March 19, 2009 Subject: Marks/Stains on Windshield When Wet (Clean Windshield) Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn and Saab) 2010 and Prior HUMMER H2, H3 Supercede: This bulletin is being revised to update the models and model years. Please discard Corporate Bulletin Number 09-08-48-002 (Section 08 - Body and Accessories). Condition Some owners may comment that marks/stains appear on the windshield when the windshield is wet. Cause This condition may be caused by contact between the windshield and the vacuum hoses or other tools used in the assembly process. This contact may leave a residue that creates a water repellent surface on the glass which, in wet conditions, appear as marks/stains on the surface. Correction Important DO NOT REPLACE THE WINDSHIELD FOR THIS CONDITION. To clean the windshield, use Eastwood Glass Polishing Compound*. Follow the manufacturer's directions for product use. Use only hand tools. DO NOT USE POWER TOOLS. Parts Information Eastwood Glass Polishing Compound 1-800-343-9353 (for overseas inquiries: +1-610-705-2200) http://www.eastwoodco.com/ *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 5576 Secondary Air Injection (AIR) Pump Relay (NU6) Secondary Air Injection (AIR) Pump Solenoid (LE5 with NU6, or LE9 with NU5) Specifications Axle Nut: Specifications Front axle nut ....................................................................................................................................... .................................................... 215 Nm (159 lb ft) TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 9210 Keyless Entry Transmitter: Tools and Equipment Special Tools Locations Fuel Pump Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 3625 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Electronic Components (MH8) Page 7566 Control Assembly: Diagrams Component Connector End Views HVAC Control Module X1 (C60) HVAC Control Module X1 (C68) Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Page 9436 7. Remove the rear upper seat back frame bolts (1). 8. Remove rear seat back bolsters. Refer to Rear Seat Back Cushion Bolster Replacement (See: Service and Repair/Removal and Replacement/Rear Seat Back Cushion Bolster Replacement). Page 546 1 - Seat Back Cover - Passenger 2 - Heated Seat Element - Passenger Back (KA1) 3 - Seat Back Cushion Pad - Passenger 4 - Seat Belt Switch - Passenger 5 - Seat Horizontal Motor - Passenger (1LZ) 6 - Seat Rear Vertical Motor - Passenger (1LZ) 7 - Heated Seat Control Module - Passenger (KA1) 8 - Seat Front Vertical Motor - Passenger (1LZ) 9 - Heated Seat Switch - Passenger (KA1) 10 - Seat Adjuster Switch - Passenger (1LZ) 11 - Inflatable Restraint Front Passenger Presence System (PPS) Module 12 - Seat Cushion - Passenger 13 - Heated Seat Element - Passenger Cushion (KA1) 14 - Seat Cover - Passenger Service and Repair Wiper Arm: Service and Repair Windshield Wiper Arm Replacement Page 4553 Locations Transmission Mode Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (MH2) 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 3598 Spark Plug: Application and ID Ignition System Specifications A/C - Poor Cooling Performance/Condenser Fan Fuse Blown Condenser Fan: All Technical Service Bulletins A/C - Poor Cooling Performance/Condenser Fan Fuse Blown TECHNICAL Bulletin No.: 09-01-38-005 Date: October 09, 2009 Subject: Poor A/C Performance, Cooling Fan Fuse Blown (Install Revised Fuse And Wiring) Models: 2008-2010 Chevrolet Malibu 2006-2010 Pontiac G6 2007-2010 Saturn AURA All with RPO LY7, LZ4, LZ9 or LZE V6 Engine Condition Some customers may comment on poor A/C cooling performance. Technicians may find that the cooling fan fuse is blown. Cause High cooling fan start up loads may cause the 30-amp cooling fan fuse, located in the underhood fuse block, to blow. The lack of air flow through the A/C condenser, caused by the inoperative high-speed cooling fan, may affect the condenser's ability to dissipate heat. Correction Use the following procedure to install a heavier gauge power feed wire from the underhood fuse block to the cooling fan. After the wiring update is completed, replace the 30-amp cooling fan fuse in the underhood fuse block with a 40-amp fuse. 1. Disconnect and remove the battery. Refer to Battery Replacement in SI. 2. Remove the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 3. Disconnect the underhood fuse block from it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. It is only necessary to raise the fuse block enough to access the harness connectors. Do not remove the complete assembly from the vehicle. 4. Locate the engine wiring harness junction block assembly (X1) on the back (underside) of the underhood fuse block and disconnect it from the underhood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 5. Find pin A2, Circuit 532, cooling fan motor supply voltage. Refer to Electrical Center Identification Views, Fuse Block-Underhood X1 in SI. 6. Remove the harness back cover. Remove the TPA (terminal position assurance) clip and remove connector A2 from the junction block. Cut the terminal off and tape the wire end with electrical tape. 7. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 8. Locate the electrical connector to the right cooling fan and disconnect the wiring connector from the fan. 9. Disengage pin B, wire 3 GY, circuit 532, cooling fan motor supply voltage, from the connector housing (pull to seat terminal). Cut the terminal off of the wire and remove the wire from the connector housing. 10. Tape the end of the wire with electrical tape. 11. Prepare a 1.82 m (6 ft) section of automotive grade 5.0 mm (10 GA) wire and an equal length of 6 mm (1/4 in) flexible plastic conduit, GM P/N 12051375. 12. Run the new wire through the fan wire connector housing as shown. 13. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 14. Strip the wire insulation as required and install the terminal, GM P/N 12033997, on the wire. Secure the wire and terminal into the fan wire Page 1580 If the engineer is unable to take your call, please leave the following information in a message: - Technician Name - Dealer Name and Phone Number - Complete VIN and Repair Order Number If the engineer is unable to respond within one hour, please proceed with normal diagnostics and repair based on the information found in SI. Warranty Information For vehicles repaired under engineering direction, use the table above. Disclaimer Page 3963 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transaxle case side cover. 2. Remove the TFP switch assembly bolts. 3. Remove the TFP switch assembly from the control valve body assembly. The TFP switch O-rings are reusable if not damaged and should remain with the switch assembly. Installation Procedure 1. Inspect the TFP switch assembly in order to verify the condition and correct location of the pressure switch O-rings. If necessary, replace the O-rings. Caution: Refer to Fastener Caution Page 330 Engine Control Module (ECM) X1 (LE5 or LE9) Page 8402 Disclaimer Page 2939 Page 5774 Fuse Block - Underhood Top View (LY7) Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: Customer Interest Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 5643 Audio Amplifier X3 (UQA) Page 9181 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Page 5310 Fuse: Locations Rear Compartment Fuse Block - Owners Manual REAR COMPARTMENT FUSE BLOCK The rear compartment fuse block is located in the trunk of the vehicle. Access the fuse block through the trunk panel on the driver side of the rear cargo area. Page 6084 * J-38125-8 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Page 9206 * J-38125-8 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Page 4495 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Electronic Components (MH8) Page 1131 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Locations Tail Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 2747 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 8882 Trunk / Liftgate Switch: Service and Repair Rear Compartment Lid Release Switch Replacement Page 9444 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Page 2761 Page 3447 5. Install the fuel tank fill pipe bolt (2) to the underbody side rail and tighten to 9 Nm (80 lb in). 6. Install the right rear wheelhouse liner. Refer to Rear Wheelhouse Panel Liner Replacement (See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Service and Repair). 7. Lower the vehicle. 8. Install the fuel tank fill pipe screws (1) to the fuel tank fill pipe housing and tighten the screws to 1.5 Nm (13 lb in). 9. Refill the fuel tank. 10. Tighten the fuel fill cap. 11. Inspect for leaks: 1. Turn ON the ignition, with the engine OFF for 10 seconds. 2. Turn OFF the ignition for 10 seconds. 3. Turn ON the ignition, with the engine OFF. 4. Inspect for fuel leaks. Page 5770 Page 2532 Throttle Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 2893 GMLAN Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If a wire is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm, etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The Page 9534 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Page 10382 Page 3834 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Remove the automatic transaxle control assembly. 2. Disconnect the Shift Lock Control Solenoid connector from the solenoid. 3. Using a flat-blade screwdriver or similar tool pry the solenoid off of the ball-sockets on the solenoid plunger and solenoid body. Page 7949 Side Air Bag: Diagrams Component Connector End Views Inflatable Restraint Side Impact Module - Left Inflatable Restraint Side Impact Module - Right Page 9144 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Page 4815 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding Hydraulic Brake System Bleeding Special Tools * J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent * J-35589-A - Master Cylinder Bleeder Adapter For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations (See: Maintenance) If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 4. Reconnect the brake pipe to the master cylinder port and tighten securely. 5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J-35589-A - Master Cylinder Bleeder Adapter to the brake master cylinder reservoir. 6. Check the brake fluid level in the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent. Add GM approved brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent, to the J-35589-A - Master Cylinder Bleeder Adapter. 8. Charge the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent,, air tank to 175-205 kPa (25-30 psi). 9. Open the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 12. Install a transparent hose over the end of the bleeder valve. 13. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. 14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 17. With the left front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left front hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 18. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 19. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 6T30/6T40/6T45 - Automatic Transmission Valve Body: Locations 6T30/6T40/6T45 - Automatic Transmission Ball Check Valve Locations Radiator Surge Tank Replacement Coolant Reservoir: Service and Repair Radiator Surge Tank Replacement Radiator Surge Tank Replacement Page 5124 Page 10092 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 2811 Page 3457 Exhaust Manifold Pipe Replacement Exhaust Pipe: Service and Repair Exhaust Manifold Pipe Replacement Exhaust Manifold Pipe Replacement Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement Sensor 2 (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor Replacement Sensor 2). 2. Remove the exhaust manifold pipe to muffler nuts. Page 5458 Page 5050 Negative: Service and Repair Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection Disconnect Procedure Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Warning: Refer to Battery Disconnect Warning (See: Service Precautions). 1. Record all of the vehicle preset radio stations. 2. Turn OFF all the lamps and the accessories. 3. Make sure the ignition switch is in the OFF position. 4. Remove the battery cover. Disengage the retainers in order to remove the cover. Page 9129 Service and Repair Hood Shock / Support: Service and Repair Hood Open Assist Rod Replacement Page 10535 Page 9039 Rear Window Trim Panel Speaker Opening Cover Replacement Rear Window Trim Panel Speaker Opening Cover Replacement Service and Repair Front Door Window Motor: Service and Repair Front Side Door Window Regulator Motor Replacement Removal Procedure Note: The driver door window regulator and motor MUST be replaced as an assembly. The right door is serviceable as door window regulator or motor. 1. Remove the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Side Door Trim Panel Replacement). 2. Remove the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Side Door Water Deflector Replacement). 3. Raise the window far enough in order to gain access to the bolts (1, 2) that attach the window to the regulator. 4. Remove the bolts (1, 2) that attach the window to the regulator. 5. Raise the window to the full up position and tape in place. 6. Disconnect the electrical connector (2) from the power window motor. 7. Remove the front door window regulator. Refer to Front Side Door Window Regulator Replacement (See: Service and Repair/Removal and Replacement/Front Side Door Window Regulator Replacement). 8. Remove the window regulator and motor through the access opening in the inner panel. 9. Remove the power window motor bolts from the window regulator. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Heated Oxygen Sensor Replacement - Sensor 1 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 1 Heated Oxygen Sensor Replacement - Sensor 1 Electrical - Various Electrical Systems Malfunctions Body Control Module: All Technical Service Bulletins Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Page 10100 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Tires/Wheels - Tire Puncture Repair Procedures Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Page 5620 Window Motor - Left Rear Window Motor - Passenger Page 5995 Page 7508 Cabin Temperature Sensor / Switch: Diagrams Component Connector End Views Air Temperature Sensor - Lower (C68) Air Temperature Sensor - Upper (C68) Page 5969 Page 10707 Disclaimer Page 1542 Specifications Firing Order: Specifications Ignition System Specifications Page 9573 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Page 1410 Page 9914 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Page 10001 A/T - Water Or Coolant Contamination Information Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Page 3672 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure 1. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 2. Disconnect the electrical connector from the park brake warning lamp switch. 3. Remove the park brake warning lamp switch screw (3). 4. Remove the park brake warning lamp switch (2) from the park brake pedal assembly (1). Installation Procedure Page 9402 Seat Rear Vertical Motor - Passenger (LTZ) Seat Recline Motor - Driver (LTZ) Page 8213 Page 1985 3. If the timing chain tensioner is not in the compressed state, perform the following steps: 1. Remove the piston assembly from the body of the timing chain tensioner by pulling it out. 2. Install the J 45027-2 (2) into a vise. 3. Install the notch end of the piston assembly into the J 45027-2 (2). 4. Using the J 45027-1 (1), turn the ratchet cylinder into the piston. 4. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint-free cloth. 5. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again. 6. At this point the tensioner should measure approximately 72 mm (2.83 in) (a) from end to end. If the tensioner does not read 72 mm (2.83 in) (a) from end to end, repeat steps 3-5. Page 1387 Body Control Module (BCM) Bottom View Page 6097 Auxiliary Power Outlet: Service and Repair Accessory AC and DC Power Control Module Replacement Accessory AC and DC Power Control Module Replacement Page 2179 Page 1240 Heater Hose: Service and Repair Heater Outlet Hose Replacement Heater Outlet Hose Replacement Special Tools J 38185 Hose Clamp Pliers Warning With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. Removal Procedure 1. Partially drain the coolant. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 2. Remove the surge tank from the surge tank bracket. 3. Reposition the heater outlet hose clamp at the heater core using the J 38185. 4. Remove the heater outlet hose from the heater core. Page 9712 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 820 Intake Air Temperature Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor (2). 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2). Installation Procedure Service and Repair Oil Change Reminder Lamp: Service and Repair ENGINE OIL LIFE SYSTEM When to Change Engine Oil This vehicle has a computer system that indicates when to change the engine oil and filter. This is based on engine revolutions and engine temperature, and not on mileage. Based on driving conditions, the mileage at which an oil change is indicated can vary considerably. For the oil life system to work properly, the system must be reset every time the oil is changed. When the system has calculated that oil life has been diminished, it indicates that an oil change is necessary. A CHANGE OIL SOON message comes on. Change the oil as soon as possible within the next 600 miles (1 000 km). It is possible that, if driving under the best conditions, the oil life system might not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. It is also important to check the oil regularly and keep it at the proper level. If the system is ever reset accidentally, the oil must be changed at 3,000 miles (5 000 km) since the last oil change. Remember to reset the oil life system whenever the oil is changed. How to Reset the Engine Oil Life System The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Whenever the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE OIL SOON message being turned on, reset the system. After changing the engine oil, reset the system: 1. Turn the ignition to ON/RUN, with the engine off. 2. Press and hold the Driver Information Center INFO and reset buttons, on the left side of the steering wheel, at the same time to enter the personalization menu. The OIL LIFE RESET message displays. 3. Press and hold the reset button until the Driver Information Center display shows ACKNOWLEDGED. 4. Turn the key to LOCK/OFF. If the CHANGE OIL SOON message comes back on when the vehicle is started, the engine oil life system has not reset. Repeat the procedure. What to Do with Used Oil Used engine oil contains certain elements that can be unhealthy for your skin and could even cause cancer. Do not let used oil stay on your skin for very long. Clean your skin and nails with soap and water, or a good hand cleaner. Wash or properly dispose of clothing or rags containing used engine oil. See the manufacturer's warnings about the use and disposal of oil products. Used oil can be a threat to the environment. If you change your own oil, be sure to drain all the oil from the filter before disposal. Never dispose of oil by putting it in the trash, pouring it on the ground, into sewers, or into streams or bodies of water. Recycle it by taking it to a place that collects used oil. Page 1553 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Page 6077 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Page 926 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) (LAT or LE5 or LE9) Knock Sensor (KS) 1 (LZ4 or LZE or LY7) Page 4178 3. Attach the park lock cable to the shift control base. Ensure the park lock cable retainer (2) is fully secured to the shift control base. 4. Install the park lock cable on the park lock lever by sliding the cable end (1) over the park lock lever pin. 5. Install the transmission range selector lever cable retainer (1) to the shift lever base. (4). 6. Install the transmission range selector lever cable terminal (2) to the shift lever pin (3). 7. Adjust the automatic transmission range selector lever cable. Refer to Range Selector Lever Cable Adjustment (See: Shift Linkage/Shift Cable/Adjustments/6T30/6T40/6T45 - Automatic Transmission). 8. Adjust the park lock cable. Refer to Park Lock Cable Adjustment (See: Parking Lock Cable/Adjustments/6T30/6T40/6T45 - Automatic Transmission). 9. Install the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). Page 3636 Control Solenoid Valve Assembly (MH8) Page 4917 12. Install the right rear park brake cable (1) or the left rear park brake cable (2) to the console park brake bracket (5) and the front park brake cable equalizer (6). 13. Install the rear carpet. Refer to Rear Floor Panel Carpet Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Removal and Replacement/Rear Floor Panel Carpet Replacement). 14. Install the front floor console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 15. Cycle the park brake pedal 4 times. Electrical - Various Electrical Systems Malfunctions Wiring Harness: Customer Interest Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Heated Oxygen and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Page 3287 5. Disconnect the engine EVAP line (1) quick connect fitting from the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 6. Remove the EVAP canister purge valve bracket bolt. 7. Remove the EVAP canister purge valve with bracket. 8. Remove the EVAP canister purge valve from the bracket. 9. Inspect for carbon release in the EVAP canister purge valve ports. If there is any loose carbon, replace the EVAP canister and any components necessary to remove the carbon particles. Installation Procedure Page 4183 5. Install the transmission range selector lever cable retainer (1) to the shift lever base. (4). 6. Install the transmission range selector lever cable terminal (2) to the shift lever pin (3). 7. Adjust the automatic transmission range selector lever cable. Refer to Range Selector Lever Cable Adjustment (See: Shift Linkage/Shift Cable/Adjustments/6T30/6T40/6T45 - Automatic Transmission). 8. Adjust the park lock cable. Refer to Park Lock Cable Adjustment (See: Parking Lock Cable/Adjustments/6T30/6T40/6T45 - Automatic Transmission). 9. Install the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). Automatic Transmission Range Selector Lever Replacement Automatic Transmission Range Selector Lever Replacement Locations Daytime Running Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 6796 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Page 1040 25 - A/Trans Fluid Pump Seal Assembly 26 - Torque Converter with Fluid Pump Housing Assembly 27 - Torque Converter and Differential Housing Bolt 28 - A/Trans Fluid Fill Tube Plug Assembly 29 - Torque Converter Assembly Component Location Component Location 1 - Reaction Carrier Assembly 2 - Control Valve Body Assembly 3 - Input Carrier Assembly 4 Valve Channel Plate 5 - Output Carrier Assembly 6 - Park Gear 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Drive Link Assembly 9 - Drive Sprocket 10 - Torque Converter Assembly 11 - A/Trans Fluid Pump Assembly 12 - Differential Carrier Assembly 13 - Front Differential Ring Gear Page 10568 Page 6314 Generator Battery Temperature Sensor 2A and Generator Battery Temperature Sensor 2B (HP7) Generator Battery Temperature Sensor 3A and Generator Battery Temperature Sensor 3B (HP7) Page 1001 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Page 5101 Key: Testing and Inspection Replacing Keys 10-Minute Vehicle Key Relearn Important: This procedure will only relearn the vehicle keys. This procedure will not learn the start enable password. Do not use this procedure as a substitute for a 10-minute relearn when replacing or reprogramming a theft deterrent module (TDM) or engine control module (ECM). Doing so will result in a failure to learn the required password. This 10-minute learn procedure should be used when all vehicle keys are desired to be replaced or reprogrammed. This procedure will erase all previously learned vehicle keys from the TDM. Once the 10-minute learn procedure has been completed, any remaining vehicle keys may be programmed using the Adding Keys procedure to ensure their continued functionality. 1. Connect a scan tool to the vehicle in the pass-thru arrangement. 2. Turn ON the ignition, with the engine OFF. 3. Ensure that all power consuming devices are turned OFF on the vehicle. 4. On the Techline Terminal, select Service Programming System and follow the Techline Terminal on-screen instructions, using the Legacy Pass-Thru method. Ensure the correct programming selection is chosen based on component being replaced or programmed. For this procedure, go to the V.T.D. Vehicle Theft Deterrent Learn menu and choose the Vehicle Theft Deterrent Learn for Learning Replacement Keys selection. 5. At this point the scan tool must remain connected for the duration of the 10-minute relearn procedure. Important: ^ The scan tool may initially display 12 Minutes. The first 2 minutes allow the scan tool to initialize the appropriate control module. The remaining 10 minutes is the relearn timer. ^ On some vehicles the security indicator may be illuminated for the duration of the 10-minute relearn procedure. 6. Observe the scan tool, after approximately 10 minutes the scan tool will display "Programming Successful, Turn OFF Ignition". The vehicle is now ready to relearn the key information and/or the passwords on the next ignition switch transition from OFF to CRANK. 7. Turn OFF the ignition and wait 2 minutes. 8. With the first vehicle key, turn the ignition to the RUN position for 15 seconds, then start the vehicle. 9. With the second vehicle key, turn the ignition to the RUN position for 15 seconds, then start the vehicle. The TDM has now learned the key transponder information. 10. With a scan tool, clear any DTCs. Page 4793 Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor assembled LRO measurement procedure, to face upward. 2. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Select the correction plate, following the manufacturer's instructions, which has a specification closest to the assembled LRO measurement. For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm (0.003 in) correction plate would be used. If the measurement was 0.127 mm (0.005 in), the 0.152 mm (0.006 in) correction plate would be used. 5. Determine the positioning for the correction plate (1) using the high spot mark (3) made during the brake rotor assembled LRO measurement procedure. Note: * Do NOT install used correction plates in an attempt to correct brake rotor assembled LRO. * Do NOT stack up, or install more than one correction plate onto one hub/axle flange location, in an attempt to correct brake rotor assembled LRO. 6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2) orientated to align with the high spot mark (3), that was positioned to face upward. Page 2762 Page 2302 Body Control Module (BCM) X4 Page 8240 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Locations Transmission Control System Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 9911 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Electrical - Various Electrical Concerns/False Messages Door Switch: All Technical Service Bulletins Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Page 9947 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 7726 Page 6880 8. Lower the vehicle. 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Testing and Inspection). Page 1099 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Locations Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Fuel Tank Components 1 - Evaporative Emission (EVAP) Canister 2 - Evaporative Emission (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly 4 - Fuel Tank Pressure (FTP) Sensor 5 - Fuel Tank Page 6079 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. Fuse Block - Underhood Relay Box: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Exploded Views Transmission Speed Sensor: Exploded Views Disassembled Views Disassembled Views Case and Associated Parts (1 of 3) 1 - Side Cover (Structural) 2 - Axle Oil Seal 3 - Side Cover Bolt 4 - Side Cover Stud 5 - Side Cover Gasket 6 - Side Cover Oil Level Control Gasket 7 - Thrust Washer (Side Cover to Driven Sprocket) 8 - Oil Pump Bolt 9 - Oil Pump Bolt 10 - Transaxle Oil Pump Assembly 11 - Transaxle Wiring Assembly 12 - TFP Manual Valve Position Switch Assembly Bolt 13 - TFP Manual Valve Position Switch Assembly 14 - Wiring Harness Pass-Through Connector O-Ring Seal 15 - Wiring Harness Bracket Bolt/Input Speed Sensor Bolt 51 - Transaxle Case 52 - Vent Cap 55 - Torque Converter Assembly 61 - Output Speed Sensor Stud 62 - Output Shaft Speed Sensor 63 - O-Ring Seal (Output Speed Sensor) 64 - Band Anchor Pin (Lo/Reverse) 65 - Oil Level Control Plug 81 - Tube Assembly Bolt/Bottom Pan Bolt 84 - Transaxle Oil Filter Seal Page 8545 Communications Control Module: Service and Repair Communication Interface Module Bracket Replacement Communication Interface Module Bracket Replacement Page 4856 Brake Fluid Level Sensor/Switch: Service and Repair Brake Fluid Level Indicator Switch Replacement Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Removal Procedure 1. Remove the brake master cylinder mounting nuts from the booster and position the master cylinder to gain access to the brake fluid level sensor but do not disconnect the brake lines. Refer to Master Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and Replacement). 2. Disconnect the electrical connector from the brake fluid level sensor. Page 4727 10. Remove the brake hose-to-caliper bolt (1) from the brake caliper. 11. Remove the brake hose (3) from the brake caliper. 12. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end (3). 13. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination. 14. Remove the brake caliper guide pin bolts (2). 15. Remove the brake caliper from the caliper bracket. 16. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following: * Restricted caliper guide pin movement * Looseness in the brake caliper mounting bracket * Seized or binding caliper guide pins * Split or torn boots 17. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement. Page 4373 4. Crimp the eared clamp (6) using J 35910, a torque wrench (8), and a breaker bar (9). 5. If equipped, install the spacer ring (2) into the groove of the halfshaft bar using J 8059. Page 7234 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Page 4475 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure Manual Valve Position Switch Replacement Removal Procedure 1. Remove the transaxle case side cover. 2. Remove the TFP switch assembly bolts. 3. Remove the TFP switch assembly from the control valve body assembly. The TFP switch O-rings are reusable if not damaged and should remain with the switch assembly. Installation Procedure 1. Inspect the TFP switch assembly in order to verify the condition and correct location of the pressure switch O-rings. If necessary, replace the O-rings. Caution: Refer to Fastener Caution Page 10053 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Page 7150 8. Remove the upper spring seat and insulator from the spring and the J 45400. Inspect for damage and replace as necessary. 9. Using the J 45400, remove the spring tension in order to remove the spring. Inspect for damage and replace as necessary. 10. Remove the dust shield and jounce bumper assembly from the strut shaft. Inspect for damage and replace as necessary. 11. Remove the lower spring seat insulator. Inspect for damage and replace as necessary. Assembly Procedure Page 797 Repair/Cooling System Draining and Filling). Page 2554 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position (CKP) system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * CKP sensor replacement * Any engine repairs which disturb the crankshaft to CKP sensor relationship Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the CKP system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensor activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the CKP system variation learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicle's transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 1802 * Trim Tool Preloader (1) * EN 45680-882 Set Gauge Ring (2) * EN 45680-883 Metal Shavings Catch Plug (3) * EN 45680-886 Drive Adapter (4) * EN 45680-884 Bolts (5) Caution: Do not bore or hone the cylinder bore sleeve. The cylinder bore sleeve inside diameter (I.D) is fully machined and honed to size and is optimally finished as shipped. Any attempt to modify this factory-produced sizing and finish with additional boring and honing will lead to engine damage, excessive noise or abnormal oil consumption. 1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange. Caution: Ensure that all the metal particles are collected in order to prevent internal damage to the engine or bearings. 2. Place the EN 45680-883 metal shaving catch plug into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-883 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve. 3. Place additional EN 45680-883 metal shaving catch plugs into all remaining cylinder bore sleeves. Page 3235 1. Lubricate the solenoid valve O-ring seals with clean engine oil. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the intake (2) CMP actuator solenoid valve and bolt, if required. Tighten the bolt to 10 Nm (89 lb in). 3. Install the exhaust (1) CMP actuator solenoid valve and bolt, if required. Tighten the bolt to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (2) to the intake CMP actuator solenoid valve (3), if required. 5. Connect the engine wiring harness electrical connector (1) to the exhaust CMP actuator solenoid valve (4), if required. 6. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 2431 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 10108 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 6559 Page 10449 Page 9156 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Page 5270 Auxiliary Power Outlet: Tools and Equipment Special Tools Locations Dimmer Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 5673 X101 Inline Harness Connector End Views X101 Left Front Wheel Speed Sensor Harness to Body Harness X102 Inline Harness Connector End Views Page 9519 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Service and Repair Scuff Plate: Service and Repair Front Side Door Sill Trim Plate Replacement Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Page 6281 Page 2254 Heat Shield: Service and Repair Exhaust Manifold Heat Shield Replacement - Left Side Exhaust Manifold Heat Shield Replacement - Left Side Removal Procedure Warning: Refer to Exhaust Service Warning (See: Service Precautions). Warning: Refer to Protective Goggles and Glove Warning (See: Service Precautions/Technician Safety Information/Protective Goggles and Glove Warning). 1. Remove the bank 2 sensor 1 heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 (). 2. Remove the exhaust manifold heat shield bolts. 3. Remove the exhaust manifold heat shield. Installation Procedure Locations Transmission Temperature Sensor/Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Fuel Pressure Gauge Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gauge Installation and Removal Fuel Pressure Gauge Installation and Removal Special Tools CH-48027-100 - Digital Pressure Gauge For equivalent regional tools, refer to Special Tools (See: Powertrain Management/Computers and Control Systems/Tools and Equipment). Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Connect the CH-48027-1 - gauge (1) to the CH-48027-2 - adapter (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027-100 - gauge, refer to the manufacture's directions. Removal Procedure Page 1739 Variable Valve Timing Solenoid: Service and Repair Camshaft Position Actuator Solenoid Valve Replacement Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (1) from the exhaust camshaft position (CMP) actuator solenoid valve (4), if required. 3. Disconnect the engine wiring harness electrical connector (2) from the intake CMP actuator solenoid valve (3), if required. 4. Remove the exhaust (1) CMP actuator solenoid valve bolt and valve, if required. 5. Remove the intake (2) CMP actuator solenoid valve bolt and valve, if required. 6. Inspect the solenoid valve O-ring seals for damage, replace as necessary. Installation Procedure Page 2734 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Center Console Components 1 - Automatic Transmission Shift Lock Control Solenoid 2 - Automatic Transmission Shift Lever Position Indicator Page 4845 11. Install the brake caliper to the vehicle. Refer to Front Brake Caliper Replacement (See: Removal and Replacement/Front Brake Caliper Replacement). Rear Brake Caliper Overhaul Rear Brake Caliper Overhaul Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). 1. Remove the rear brake caliper from vehicle. Refer to Rear Brake Caliper Replacement (See: Removal and Replacement/Rear Brake Caliper Replacement). Note: If the brake caliper was leaking brake fluid from the REAR of the caliper past the integral park brake actuator shaft seal, replace the brake caliper assembly. The park brake integral mechanism contains a non-serviceable seal which may be allowing brake fluid to leak past it and into the non-serviceable integral park brake mechanism. 2. Drain the brake fluid from the caliper assembly. 3. Using a small wooden or plastic tool, carefully remove the brake caliper piston dust boot seal retaining ring from the groove in the caliper seal counterbore. 4. Place a block of wood against the inside of the caliper body, opposite of the caliper piston. 5. Direct low pressure compressed air through the caliper inlet hose to remove the caliper piston. Page 2822 Page 4500 64 - Band Anchor Pin (Lo/Reverse) 65 - Oil Level Control Plug 81 - Tube Assembly Bolt/Bottom Pan Bolt 84 - Transaxle Oil Filter Seal 85 - Transaxle Oil Filter Assembly 86 - Oil Level Control Valve 87 - Transaxle Bottom Pan Gasket 88 - Transaxle Oil Pan 89 - Chip Collector Magnet 120 Chip Collector Magnet (Some Models) 126 - Side Cover Stud 130 - A/Trans Auxiliary Fluid Pump Assembly 131 - Auxiliary Trans Fluid Pump Bolts 132 - Auxiliary Pump Pipe Bolts Component Location Component Location Transmission Major Components 1 - TFP Manual Valve Position Switch Assembly 2 - Control Valve Body Assembly Page 9978 Electrical - Various Electrical Systems Malfunctions Body Control Module: Customer Interest Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Page 5449 Page 2814 Page 909 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. (Intake CMP shown, exhaust CMP similar). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect engine wiring harness electrical connector (5) to the exhaust CMP sensor (4). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 6942 Steering Control Module: Diagrams Component Connector End Views Electric Power Steering (EPS) Module X1 (without NVH) Electric Power Steering (EPS) Module X2 (without NVH) Page 1260 13. Remove the suction hose. Note: Cap all A/C components immediately to prevent system contamination. 14. Remove and discard the sealing washers. Installation Procedure 1. Uncap A/C components. 2. Install new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 3. Install the suction hose. Page 9899 Page 3851 25 - Torque Converter and Support and A/Trans Fluid Pump Housing Assembly 26 - Torque Converter and Differential Housing Bolt 27 - Torque Converter Assembly 28 - Dust Cover Push Pin - Model Dependent 29 - Dust Cover Bolt - Model Dependent 30 - Dust Cover - Model Dependent 31 - Front Differential Carrier Assembly 32 - Input Shaft Thrust Bearing Assembly 33 - A/Trans Case Cover Gasket 34 - A/Trans Case Cover Assembly 35 - A/Trans Case Cover Assembly Bolt A/C - Window Defroster Contact/Tab Repair Information Back Window Glass: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Auxiliary Power Outlet: Service and Repair Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Cigar Lighter Receptacle or 12-Volt Accessory Power Receptacle Replacement Special Tools J 42059 Cigar Lighter Socket Remover Removal Procedure 1. Remove the auxiliary power outlet fuse from the fuse block. 2. Remove the receptacle: 1. Look into the receptacle. There are two 3 mm (0.11 in) tab windows 12 mm (0.47 in) from the front of the receptacle. The J 42059 pushes the plastic latches from these tab windows and the receptacle can be pulled straight out. 2. Place one side of the "T" portion of the J 42059 into the tab window. The J 42059 will not fit straight into the receptacle. Angle the J 42059 slightly for insertion into the receptacle. 3. Insert the other side of the "T" into the opposite tab window. You must move the J 42059 handle toward horizontal to engage the other tab window. 4. Use the J 42059 to pull the receptacle straight out. Page 2422 Page 5206 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Page 6366 Intake Manifold Tuning (IMT) Solenoid Valve (LY7) Page 7757 2. Install the lower air temperature sensor. 3. Install the right front floor console extension panel. Refer to Front Floor Console Extension Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Extension Panel Replacement - Right Side). Page 6379 Outside Rearview Mirror - Passenger (DD0) Outside Rearview Mirror - Passenger (D49 or DP2) 6T30/6T40/6T45 - Automatic Transmission Shift Solenoid: Specifications 6T30/6T40/6T45 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Exhaust Manifold Replacement - Left Side Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Side Exhaust Manifold Replacement - Left Side Special Tools J 39194-B Heated Oxygen Sensor Wrench Removal Procedure Caution: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. Caution: The use of excessive force may damage the threads in the exhaust manifold/pipe. Note: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the heated oxygen sensor (HO2S). Note: The HO2S may be difficult to remove when the engine temperature is less than 48°C (120°F) 1. Remove the air intake duct. Refer to Air Cleaner Inlet Duct Replacement (See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Inlet Duct Replacement). 2. Remove the connector position assurance (CPA) retainer (5). 3. Disconnect the engine wiring harness electrical connector (4) from the HO2S electrical connector (3). 4. Remove the HO2S electrical connector rosebud clip from the oil level indicator tube tab. Page 5250 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. Page 4298 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Component Location Component Location Component Locations 1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear Support Assembly Page 7432 Air Door Actuator / Motor: Service and Repair HVAC - Manual Air Inlet Valve Actuator Replacement Air Inlet Valve Actuator Replacement Mode Valve Actuator Replacement Mode Valve Actuator Replacement Locations Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 4593 Page 589 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Page 10802 7. Remove the wiper motor (1). Refer to Windshield Wiper Motor Replacement (See: Windshield Wiper Motor Replacement). Installation Procedure 1. Install the wiper motor (1). Refer to Windshield Wiper Motor Replacement (See: Windshield Wiper Motor Replacement). 2. Connect the electrical connector to the wiper motor. Locations Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) Page 2871 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 5423 Door Latch - Driver Door Latch - Left Rear Page 189 Page 3775 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 711 Ambient Light Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C60) Page 5523 Inflatable Restraint I/P Module Inflatable Restraint I/P Module Indicator Page 4548 1 - Control Valve Body Cover Assembly 2 - Transmission Fluid Level Indicator Assembly 3 - Fluid Level Indicator Tube - Model Dependent 4 - Fluid Level Indicator Tube Seal - Model Dependent 5 Control Valve Body Cover Assembly Gasket 6 - Control Valve Body Cover Stud 7 - Control Valve Body Cover Bolt 8 - Control Valve Body Bolt 9 - Control Valve Body Bolt 10 - Control Valve Body Cover Wiring Connector Hole Seal 11 - Control Solenoid Valve Spring 12 - Control Valve Body Bolt 13 - Control Valve Body Bolt 14 - Control Valve Body Bolt 15 - Control Solenoid (w/Body and TCM) Valve Assembly 16 - Control Solenoid (w/Body and TCM) Filter Plate Assembly 17 - Manual Shaft Detent Assembly 18 - Control Valve Body Assembly 19 - A/Trans Output Speed Sensor Assembly 20 - A/Trans Output Speed Sensor Bolt 21 - A/Trans Case Assembly 22 - Torque Converter Housing Outer Seal 23 - Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly 24 Front Differential Drive Pinion Gear Lube Tube Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure Important: If replacing the steering wheel position sensor, the new sensor MUST come with a locating pin installed. If a locating pin is not installed, return and reorder a new steering wheel position sensor. Do not apply force to the steering wheel position sensor in a sideways direction. When reusing the steering wheel position sensor you must install a locating pin before removing it from the steering column. If the steering wheel position sensor loses its correct position it must be discarded. The locating pin diameter must be in the range of 1.0-2.0 mm. 1. Set the front wheels in the straight-ahead position and install anti-rotation pin J 42640 in the steering column lower access hole. 2. Disconnect the intermediate steering shaft from the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 3. Disconnect any electrical connectors as needed. 4. Remove the steering wheel position sensor. Assembly Procedure Locations Fog/Driving Lamp Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 1991 17. If replacing the balance shaft timing chain and sprocket, perform the following steps, if not proceed to step 10 in the installation procedure. 18. Remove the balance shaft drive chain tensioner bolts and tensioner. 19. Remove the adjustable balance shaft chain guide bolt and guide. Page 4635 85 - Transaxle Oil Filter Assembly 86 - Oil Level Control Valve 87 - Transaxle Bottom Pan Gasket 88 - Transaxle Oil Pan 89 - Chip Collector Magnet 120 - Chip Collector Magnet (Some Models) 126 - Side Cover Stud 127 - Transmission Wiring Harness Assembly (Some Models) 128 - Electrical Connector Retaining Bracket (Some Models) Case and Associated Parts - L4 Hybrid 1 - Side Cover (Structural) 2 - Axle Oil Seal 3 - Side Cover Bolt 4 - Side Cover Stud 5 - Side Cover Gasket 6 - Side Cover Oil Level Control Gasket 7 - Thrust Washer (Side Cover to Driven Sprocket) 8 - Oil Pump Bolt 9 - Oil Pump Bolt 10 - Transaxle Oil Pump Assembly 11 - Transaxle Wiring Assembly 12 - TFP Manual Valve Position Switch Assembly Bolt 13 - TFP Manual Valve Position Switch Assembly 15 - Wiring Harness Bracket Bolt/Input Speed Sensor Bolt 51 - Transaxle Case 52 - Vent Cap 55 - Torque Converter Assembly 61 - Output Speed Sensor Stud 62 - Output Shaft Speed Sensor 63 - O-Ring Seal (Output Speed Sensor) Page 8718 Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Extension Replacement Air Inlet Grille Panel Extension Replacement Page 8078 Disclaimer Page 3202 4. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 5. Install the shift control cable to transaxle range switch lever and verify proper operation. Page 3328 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 adapter (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 - adapter (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 - adapter (2). 5. Remove the hose on the CH-48027-2 - adapter (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 - gauge (1) from the CH-48027-2 - adapter (2). 3. Disconnect the CH-48027-2 - adapter (2) from the CH-48027-2 - adapter (3). 4. Disconnect the CH-48027-2 adapter (3) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Install the engine cover, if required. 7. Tighten the fuel fill cap. Page 7883 Impact Sensor: Diagrams Component Connector End Views Inflatable Restraint Front End Sensor - Left Inflatable Restraint Front End Sensor - Right Inflatable Restraint Side Impact Sensor (SIS) - Left Page 6327 Heated Seat Control Module - Passenger X2 (KA1) Exploded Views Transmission Speed Sensor: Exploded Views Disassembled Views Disassembled Views Case and Associated Parts (1 of 3) 1 - Side Cover (Structural) 2 - Axle Oil Seal 3 - Side Cover Bolt 4 - Side Cover Stud 5 - Side Cover Gasket 6 - Side Cover Oil Level Control Gasket 7 - Thrust Washer (Side Cover to Driven Sprocket) 8 - Oil Pump Bolt 9 - Oil Pump Bolt 10 - Transaxle Oil Pump Assembly 11 - Transaxle Wiring Assembly 12 - TFP Manual Valve Position Switch Assembly Bolt 13 - TFP Manual Valve Position Switch Assembly 14 - Wiring Harness Pass-Through Connector O-Ring Seal 15 - Wiring Harness Bracket Bolt/Input Speed Sensor Bolt 51 - Transaxle Case 52 - Vent Cap 55 - Torque Converter Assembly 61 - Output Speed Sensor Stud 62 - Output Shaft Speed Sensor 63 - O-Ring Seal (Output Speed Sensor) 64 - Band Anchor Pin (Lo/Reverse) 65 - Oil Level Control Plug 81 - Tube Assembly Bolt/Bottom Pan Bolt 84 - Transaxle Oil Filter Seal Page 10631 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Page 5223 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 6114 Warranty Information (Saab U.S. Models) Disclaimer Page 5970 Page 4323 6. Install the side cover assembly onto the transmission case. 7. Install the 11 side cover bolts (3) or studs (4) (model dependent). 8. Refer to the graphic in order to find the correct installation points of the bolts and the stud. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Hand start the bolts. Tighten the side cover bolts and stud to 28 Nm (22 lb ft). 10. Lower the vehicle. 11. Raise the engine with the engine support fixture. 12. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 13. On vehicles equipped with the L61 engine, install the transmission mount. Refer to Transmission Mount Replacement - Left Side (See: Transmission Mount/Service and Repair/6T70/6T75 - Automatic Transmission/Transmission Mount Replacement - Left Side). 14. Install the frame. Refer to Frame Replacement (See: Body and Frame/Frame/Service and Repair). 15. Install the power steering intermediate shaft and tie-rod ends. Refer to Steering Gear Replacement (See: Steering and Suspension/Steering/Steering Gear/Service and Repair/Steering Gear Replacement). 16. Install the wheel drive shaft to the transmission. Refer to Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Page 8139 Installation Procedure 1. Install the coaxial cable to inner body side. 2. Install the coaxial cable to the front roof bow. 3. Install the rear window shelf panel. Refer to Rear Window Shelf Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Shelf Trim Panel Replacement). 4. Install the headliner. Refer to Headlining Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair ). Page 3134 1. Install the fuel level sensor (1) to the alignment feature (2). 2. Allow the locking tab (2) to lock into place. 3. Connect the fuel level sensor electrical connector (1). 4. Install the fuel pump module assembly. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder Replacement Page 9770 Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Replacement Brake Pedal Position Sensor Replacement Locations Yaw Rate Sensor: Locations Passenger Compartment/Roof Component Views Roof/Headliner and Under the Center Console Components 1 - Inflatable Restraint Roof Rail Module - Right Front 2 - Inflatable Restraint Roof Rail Module Left Front 3 - Yaw and Lateral Accelerometer Sensor 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Page 6200 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 8024 Enabling Procedure - Air Bag Fuse 1. Place the ignition in the OFF position. 2. Install the fuse(s) supplying power to the SDM. Refer to SIR Schematics (See: Air Bag Systems/Diagrams/Electrical Diagrams) or Electrical Center Identification Views (See: Maintenance/Fuses and Circuit Breakers/Fuse/Application and ID). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Disabling Procedure - Negative Battery Cable 1. Turn the steering wheel so that the vehicles wheels are pointing straight ahead. 2. Place the ignition in the OFF position. 3. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 4. Wait 1 minute before working on system. Enabling Procedure - Negative Battery Cable 1. Place the ignition in the OFF position. 2. Connect the negative battery cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Turn the ignition switch to the ON position. The AIR BAG indicator will flash then turn OFF. 4. Perform the Diagnostic System Check - Vehicle if the AIR BAG warning indicator does not operate as described. Refer to Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle). Page 2812 Page 9849 Rear Door Weatherstrip: Service and Repair Rear Door Opening Weatherstrip Replacement Rear Door Opening Weatherstrip Replacement Page 4173 2. Install the shift knob retaining screw (3) and tighten to 4 Nm (35 lb in). 3. Install the boot (2) to the console. Interior - Gap At Rear Edge Of Shifter Trim Plate Console: All Technical Service Bulletins Interior - Gap At Rear Edge Of Shifter Trim Plate TECHNICAL Bulletin No.: 08-08-49-012B Date: September 21, 2009 Subject: Gap at Rear Edge of Front Floor Console Shifter Trim Plate (Align Mounting Tab) Models: 2008-2010 Chevrolet Malibu Supercede: This bulletin is being revised to add the 2010 model year and to update the Correction information. Please discard Corporate Bulletin Number 08-08-49-012A (Section 08 - Body and Accessories). Condition Some customers may comment on a gap at the rear edge of the floor console shifter trim plate. Cause This condition may be caused by the front floor console accessory trim plate rear clips not fully engaging with the clip slots in the console base. Correction Use the following steps to remove the front floor console accessory trim plate and inspect the trim plate clip towers, clips and the console clip slots for damage. If no damage is found, reinstall the trim plate as described in the procedure. 1. Set the parking brake. 2. Turn the ignition key to the ON position with the engine off (the engine should not be running). 3. Depress the brake pedal and place the shifter into the neutral ("N") position. Note Release the shifter boot from the shifter knob by pulling the boot retainer down in order to gain access to the shift knob front retaining screw. 4. Remove the shift control knob. Refer to Floor Shift Control Knob Replacement in SI. 5. Remove the front floor console trim plate. Refer to Front Floor Console Accessory Trim Plate Replacement in SI. 6. Inspect the underside of the shifter console trim plate for the four white attaching clips and their rib structures. - Inspect all of the shifter plate attachments, including the two small forward tabs. If none of the attachments are damaged and the shifter plate forward tip up bin lid functions properly, DO NOT REPLACE the shifter trim plate. - If any of the four attaching clips are damaged or bent, the console shifter trim plate may need to be replaced. 7. Remove the left and right console side extension panels to provide access to the clip slots in the console base from below. Refer to Front Floor Console Extension Panel Replacement in SI. 8. Position the front floor console accessory trim plate for installation. Refer to Front Floor Console Accessory Trim Plate Replacement in SI. Page 6472 Audio Amplifier X3 (UQA) Page 5211 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 3142 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 3271 1. Install a NEW gasket to the left (front) catalytic converter studs. 2. Install the left (front) catalytic converter (4). 3. Install a NEW gasket (6) to the right (rear) catalytic converter studs. 4. Install the right (rear) catalytic converter (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the right (rear) catalytic converter bolt (5) and nuts (1) at the exhaust manifold and tighten to 45 Nm (33 lb ft). 6. Install the left (front) catalytic converter to right (rear) catalytic converter nuts (3) and tighten to 25 Nm (18 lb ft). Note: A special anti-seize compound is used on the HO2S threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 7. If reinstalling the old HO2S, coat the threads with anti-seize compound. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Exhaust System/Specifications/Fluid Type Specifications) Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Page 766 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor (2). 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2). Installation Procedure Page 9180 Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Page 9936 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Service and Repair Hood Latch: Service and Repair Hood Primary and Secondary Latch Replacement Page 5317 Body Control Module (BCM) X1 Service and Repair License Plate Bracket: Service and Repair Rear License Plate Lamp Bezel Replacement Page 3764 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 2349 Engine Control Module (ECM) X1 (LE5 or LE9) Locations Throttle Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left Side of the Instrument Panel Components (1 of 2) 1 - Brake Pedal Position (BPP) Sensor 2 - Accelerator Pedal Position (APP) Sensor 3 - Accelerator Pedal 4 - Brake Pedal Page 9670 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Locations Power Door Lock Switch: Locations Door Component Views Driver Door Components 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Passenger Door Components Page 9949 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 2479 5. Connect the fuel injector wiring harness electrical connector (1) to the MAP sensor. 6. Position the EVAP canister purge tube (1) out of the way. 7. Connect the EVAP canister purge tube to the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 8. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 2412 2. Measure from the same end as earlier, and slide the current sensor to that measurement on the negative battery cable. 3. Install the battery negative cable. Refer to Battery Negative Cable Replacement (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Replacement). Page 9357 Removal Procedure 1. Open the rear compartment 2. It is only necessary to lower the headliner. Only perform the steps in headliner replacement procedure that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (See: Interior Moulding / Trim/Headliner/Service and Repair). 3. Remove the rear compartment trim panel. Refer to Rear Compartment Trim Panel Replacement (See: Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Compartment Trim Panel Replacement). 4. Disconnect the rear sunroof drain hose from the sunroof drain spigot. 5. Disengage the sunroof drain hose from the attachment clips on the roof rail, the C-pillar, and the rear compartment. 6. Disconnect the drain hose from the grommet seated in the rear lower quarter panel. 7. Remove the drain hose into the passenger compartment by pulling the hose through the access hole in the rear package shelf. 8. If necessary, pull the grommet into the rear compartment to remove. Installation Procedure Campaign - Airbag Readiness Light/Service Airbag Message Technical Service Bulletin # 10085D Date: 110203 Campaign - Airbag Readiness Light/Service Airbag Message CUSTOMER SATISFACTION Bulletin No.: 10085D Date: February 03, 2011 Subject: 10085D - Airbag Readiness Light/Service Airbag Message - Replace Connectors Models: 2008 Buick Enclave 2010 Chevrolet Malibu 2008 GMC Acadia 2010 Pontiac G6 2008 Saturn OUTLOOK Supercede: The Service Procedure in this bulletin has been revised. All vehicles will not require the replacement of the front seat-mounted side impact airbag connectors.Please discard all copies of bulletin 10085C, issued November 2010. Condition Certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may experience wear which could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact air bag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG System warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG System DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Correction Dealers are to replace the front seat-mounted side impact airbag connectors. Vehicles Involved Involved are certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Part Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your Page 5602 Tail/Stop and Turn Signal Lamp - Right (LTZ) Page 6283 Campaign - Service Air Bag Message, Replace Connectors Technical Service Bulletin # 11034 Date: 110314 Campaign - Service Air Bag Message, Replace Connectors CUSTOMER SATISFACTION Bulletin No.: 11034 Date: March 14, 2011 Subject: 11034 - Service Air Bag Message - Replace Connectors Models: 2010 Chevrolet Malibu 2010 Pontiac G6 Some, but not all, of the vehicles involved in this Program were also involved in Customer Satisfaction Program (CSP) 10085. These vehicles are to be inspected to determine if the repair for CSP 10085 included the replacement of the two connectors. If the connectors were replaced, no further action is required on these vehicles. If they were not replaced, dealers are to install the new connectors. Condition Certain 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may have a condition in which wear could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact airbag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG system warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG system DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Some of these vehicles were previously repaired under Customer Satisfaction Program 10085. These vehicles had the wire harness secured, and in some cases, rerouted. They did not require the installation of the two connectors. However, there have been reports of the SERVICE AIR BAG message illuminating in the Driver Information Center after the repair, due to movement of the connector between the body main wiring harness and the front driver and passenger side impact air bag. With this Customer Satisfaction Program, dealers will install the two new connectors. Correction Dealers are to inspect and, if necessary, replace the front seat-mounted side impact air bag connectors. Vehicles Involved Involved are certain 2010 model year Chevrolet Malibu and Pontiac G6 vehicles. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty Management system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Page 5178 Page 1637 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Page 5901 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3680 8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95. 10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body and transmission control module (TCM) assembly (5). Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 12. Remove the control solenoid valve assembly filter plate (6). * Discard the filler plate. It is not reusable. * Inspect the pressure switch manifold seals for damage or contamination. Replace the control solenoid valve assembly as necessary. * Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage around the PCS seals. Replace the upper channel plate as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (1). Locations Oxygen Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Lower Front and Rear of the Engine Components (LY7) Page 5775 Fuse Block - Underhood Top View (LZ4 or LZE) Page 10034 Page 1313 7. Inspect the fluid color. The fluid should be red or dark brown. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal particles or other debris. A small amount of "friction" material is a "normal" condition. If large pieces and/or metal particles are noted in the fluid, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs of transmission internal damage noted, replace the fluid, repair the oil cooler, and flush the cooler lines. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic Procedures/6T30/6T40/6T45 - Automatic Transmission/Engine Coolant/Water in Transmission). 8. Inspect for external leaks. Refer to Fluid Leak Diagnosis (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/6T30/6T40/6T45 - Automatic Transmission/Fluid Leak Diagnosis). 9. If the fluid was changed, reset the transmission oil life monitor if applicable. Dipstick Level Checking Procedure (If equipped) 1. Park the vehicle on a level surface, apply the parking brake and place the shift lever in PARK (P). Start the engine. 2. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in each range. Then move the shift lever back to PARK (P). 3. Allow the engine to idle 500-800 rpm for at least 3 minutes to allow any fluid foaming to dissipate and the fluid level to stabilize. Release the brake pedal. 4. Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver Information Center or a scan tool. Caution: The transmission fluid level must be checked when the transmission fluid temperature (TFT) is at 85-95°C (185-203°F). If the TFT is not at this temperature, operate the vehicle or allow the fluid to cool as required. Setting the fluid level with a TFT outside this temperature will result in either an under or over-filled transmission. TFT 95°C under-filled, TFT 85°C over-filled. An under-filled transmission will cause premature component wear or damage. An over-filled transmission will cause fluid to discharge out the vent tube, fluid foaming, or pump cavitation. Note: * If the TFT reading is not at the required temperature, allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached. If the fluid temperature is below the specified range, perform the following procedure to raise the fluid temperature to the specification. * Check the transmission fluid level when the TFT is at between 85-95°C (185-203°F). The fluid level rises as fluid temperature increases, so it is important to ensure the transmission fluid temperature is at the specified temperature. Drive the vehicle in second gear until the fluid temperature is at the specified temperature. 5. The vehicle must be level, with the engine running and the shift lever in the PARK range. 6. Remove the dipstick and wipe it with a clean rag or paper towel. 7. Inspect the fluid color. The fluid should be red or dark brown. * If the fluid color is very dark or black and has a burnt odor, inspect the fluid for excessive metal particles or other debris. A small amount of "friction" material is a "normal" condition. If large pieces and/or metal particles are noted in the fluid, flush the oil cooler and cooler lines and overhaul the transmission. If there are no signs of transmission internal damage noted, replace the fluid, repair the oil cooler, and flush the cooler lines. * Fluid that is cloudy or milky or appears to be contaminated with water indicates engine coolant or water contamination. Refer to Engine Coolant/Water in Transmission (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Symptom Related Diagnostic Procedures/6T30/6T40/6T45 - Automatic Transmission/Engine Coolant/Water in Transmission). 8. Install the dipstick. Wait three seconds and then remove it again. Note: Always check the fluid level at least twice. Consistent readings are important to maintaining proper fluid level. If inconsistent readings are noted, inspect the transmission vent cap to ensure it is clean and unclogged. Note: It is not necessary to get the fluid level all the way up to the MAX mark. Anywhere within the crosshatch band is acceptable. 9. Check both sides of the dipstick and read the lower level. 10. Install and remove the dipstick again to verify the reading. Note: Do not add more than one half pint (0.25L) at a time without rechecking the level. Once the oil is on the dipstick bullet, it will not take much more fluid to raise the fluid level into the crosshatch band. Do not overfill. Also, if the fluid level is low, inspect the transmission for leaks. Refer to Fluid Leak Diagnosis (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Component Tests and General Diagnostics/6T30/6T40/6T45 - Automatic Transmission/Fluid Leak Diagnosis). 11. If the fluid level is not within the crosshatch band, and the transmission temperature is at 90°C (194°F), add or drain fluid as necessary to bring the level into the crosshatch band. If the fluid level is low, add only enough fluid to bring the level into the crosshatch band. 12. If the fluid level is in the acceptable range, install the dipstick. Page 6428 Sunshade - Right (LTZ) Tail/Stop and Turn Signal Lamp - Left (without LTZ) Page 3719 85 - Transaxle Oil Filter Assembly 86 - Oil Level Control Valve 87 - Transaxle Bottom Pan Gasket 88 - Transaxle Oil Pan 89 - Chip Collector Magnet 120 - Chip Collector Magnet (Some Models) 126 - Side Cover Stud 127 - Transmission Wiring Harness Assembly (Some Models) 128 - Electrical Connector Retaining Bracket (Some Models) Case and Associated Parts - L4 Hybrid 1 - Side Cover (Structural) 2 - Axle Oil Seal 3 - Side Cover Bolt 4 - Side Cover Stud 5 - Side Cover Gasket 6 - Side Cover Oil Level Control Gasket 7 - Thrust Washer (Side Cover to Driven Sprocket) 8 - Oil Pump Bolt 9 - Oil Pump Bolt 10 - Transaxle Oil Pump Assembly 11 - Transaxle Wiring Assembly 12 - TFP Manual Valve Position Switch Assembly Bolt 13 - TFP Manual Valve Position Switch Assembly 15 - Wiring Harness Bracket Bolt/Input Speed Sensor Bolt 51 - Transaxle Case 52 - Vent Cap 55 - Torque Converter Assembly 61 - Output Speed Sensor Stud 62 - Output Shaft Speed Sensor 63 - O-Ring Seal (Output Speed Sensor) Page 4965 Page 1929 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Special Tools CH-48027 - Digital Pressure Gauge For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). 1. With the vehicle on a level surface, allow adequate drain down time of 2-3 minutes and measure for a low oil level. Add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator. 2. Run the engine, and verify low, or no oil pressure on the vehicle gauge or light. Listen for a noisy valve train or a knocking noise. 3. Inspect for the following: * Correct oil filter with anti-drain back feature and O-ring on the cylinder block side of the filter * Oil diluted by moisture or unburned fuel mixtures * Improper oil viscosity for the expected temperature * Incorrect or malfunctioning oil pressure sender * Incorrect or malfunctioning oil pressure gauge * Plugged oil filter * Malfunctioning oil bypass valve 4. Remove the oil pressure sender or another engine block oil gallery plug. 5. Install CH-48027 adapter and oil pressure gauge and measure the engine oil pressure. 6. Compare the readings to specifications. Refer to Engine Mechanical Specifications (See: Specifications/Service Limits & General Specifications ). 7. If the engine oil pressure is below specifications, inspect the engine for one or more of the following: * Correct oil filter with anti-drain back feature and O-ring on the cylinder block side of the filter * Oil pump worn or dirty Refer to Oil Pump Disassemble (See: Service and Repair/Overhaul/38. Oil Pump Disassemble). * Oil pump-to-engine front cover bolts loose Refer to Engine Front Cover and Oil Pump Installation (See: Service and Repair/Overhaul/58. Engine Front Cover and Oil Pump Installation ). * Oil pump screen loose, plugged, or damaged * Oil pump screen O-ring seal missing or damaged * Malfunctioning oil pump pressure regulator valve * Excessive bearing clearance Refer to Crankshaft and Bearing Cleaning and Inspection (See: Service and Repair/Overhaul/26. Crankshaft and Bearing Cleaning and Inspection). * Cracked, porous or restricted oil galleries * Oil gallery plugs missing or incorrectly installed Refer to Engine Block Assemble (See: Service and Repair/Overhaul/45. Engine Block Assemble). * Broken lash adjusters Page 1638 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Diagrams Windshield Washer Pump: Diagrams Component Connector End Views Windshield Washer Fluid Pump Page 6593 Page 1280 Power Steering Line/Hose: Service and Repair Power Steering Gear Outlet Pipe/Hose Replacement Power Steering Gear Outlet Pipe/Hose Replacement Special Tools J-44586 - Power Steering Gear Oil Seal Remover/Installer Removal Procedure 1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). 2. Remove as much power steering fluid from the power steering fluid reservoir as possible. 3. Place drain pans under the vehicle as needed. 4. Compress the power steering gear outlet hose clamp (1) and disconnect the power steering reservoir inlet pipe (2) from the power steering gear outlet hose (3). 5. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). Page 7761 Refrigerant Pressure Sensor / Switch: Diagrams Component Connector End Views A/C Refrigerant Pressure Sensor Page 1160 Spark Plug: Application and ID Ignition System Specifications Page 4738 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the 2 brake caliper guide pin bolts and tighten to 35 Nm (26 lb ft). 9. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 10. Lower the vehicle. 11. Fill the master cylinder to the proper level. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 12. Pump the brake pedal 2-3 times in order to seat the rear disc brake pads to the rotor. Front Brake Caliper Bracket Replacement Front Brake Caliper Bracket Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Page 6591 Diagrams Trunk / Liftgate Latch: Diagrams Component Connector End Views Rear Compartment Lid Latch Page 5651 Automatic Transmission Output Shaft Speed (OSS) Sensor (MH2 or MH8) Page 5870 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 7518 Compressor Clutch: Diagrams Component Connector End Views A/C Compressor Clutch Page 6494 Body Control Module (BCM) X4 Page 5993 Page 7445 Air Duct: Service and Repair Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side Instrument Panel Outer Air Outlet Upper Duct Replacement - Left Side Removal Procedure 1. Remove the instrument panel (I/P) assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). 2. Disconnect the wire harness clip at the left air outlet duct. 3. Remove the left air outlet duct screws. 4. Remove the left air outlet duct. Installation Procedure Page 6328 Heated Seat Control Module - Passenger X3 (KA1) Page 952 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front Page 6521 X310 Inline Harness Connector End Views X310 Body Harness to Passenger Seat Harness Page 10534 Turn Signal Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Page 7090 1. Install the bushing on the lower control arm as previously noted. 2. Using LOCKTITE(TM) 234 or equivalent on the bolt threads, install the lower control arm to bushing bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Hold the rear bushing inner sleeve when tightening the rear bushings to control arm bolt and tighten to 44 Nm (32 lb ft). 4. Install the lower control arm. Refer to Lower Control Arm Replacement (See: Service and Repair/Front Suspension). 5. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 6. Lower the vehicle. Page 5255 * J-38125-8 - Splice Sleeve Crimp Tool * J-38125-5 - Ultra Torch For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: All repairs near the engine manifold, turbo engine and all exhaust pipes should follow the High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) procedures. Terminated leads are terminals that are crimped onto wires. The terminated lead can be used throughout the vehicle since it is designed for temperatures up to 150°C. The length of the wire is 450 mm. The DuraSeal splice sleeve has the following 2 critical features: * A special heat shrink tubing that environmentally seals the splice. The shrink tubing contains a sealing adhesive inside the shrink tubing. * A cross hatched (knurled) core crimp that provides the necessary contact integrity for sensitive low energy circuits. 1. Use the connector end view to identify the correct terminated lead. 2. The terminated lead package should include a DuraSeal splice sleeve. If not, use the chart to identify the correct part. 3. Open the harness by removing any tape: Use a sewing seam ripper, or a comparable tool, to cut open the harness, to avoid wire insulation damage. 4. Depending on how many terminals need repairs, cut the terminal and wire back at least 40 mm. Try to keep the harness wire length the same. If more than one terminated lead is required, stagger the lengths by 40 mm. This helps reduce the bundle size of the wire harness. 5. Use the EL-38125-10 - tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. The crimp tool has four nests, one for each color. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. Specifications Ball Joint: Specifications Ball Joint Wear Limit ............................................................................................................................ ...................................................... 0.5 mm (0.02 in) Page 373 Page 2625 TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Locations Transmission Speed Sensor: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH2) Page 6786 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Page 10620 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Left Side Front Side Door Window Switch Replacement - Left Side Page 6347 Ignition Coil 5 (LY7) Page 4474 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (ME7 or MN5) Page 6055 3. To assemble the connector, reverse the connector disassembly procedure. Tyco/AMP Connectors Tyco/AMP Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure 1. Using your thumbs press down and slide the red CPA away from the connector lever. 2. Using your thumb press down on the locking tab and move the lever to the released position. Page 5997 Page 4038 Page 412 Page 4351 - Select "Z" - Select "Aura" - Select "Powertrain" - Select "3.6L LY7" - Select "Transmission" - Select "Transmission Data" 5. From the application menu, select F3: Snapshot. - Choose trigger type and trigger point, as described above. - It is preferred to trigger on "Any Code" (F1) - If multiple codes are setting, select "Single Code" and enter the code you are trying to capture on the next screen. - Select "Center (F5)" for the trigger point. This allows the requester/viewer of the data to see the events before and after the code sets. 6. Press the Record Snapshot soft key. The Tech 2(R) screen will display the parameters it is going to record for live viewing. - When the fault occurs, the Tech 2(R) will automatically start recording if the preferred settings (F1 and F5) are selected. - If manual trigger is selected during the setup procedure, you will have to hit the "Trigger" soft key to actually record data. Otherwise, it will automatically start recording when a DTC is set. - Allow the Tech 2(R) to record the data. Please note that a Tech 2(R) can record a maximum of 1 minute of data (30 seconds before and 30 seconds after the trigger point if center trigger is selected). Important The Tech(R)2 can only record two snapshots prior to uploading to a computer. If a third snapshot is requested, the first snapshot will be overwritten. 7. When the snap shot data has been recorded, exit to the Main Menu, then power down and disconnect the Tech 2(R) from the vehicle. Uploading and Sending a Snapshot via TIS2WEB Figure 8 Page 7521 7. Remove the compressor pulley from the compressor. 8. Remove the compressor clutch coil snap ring using the J 6083. Page 7892 Seat Occupant Sensor: Locations Passenger Compartment/Roof Component Views Seat Components - Passenger 1 - Seat Back Cover - Passenger 2 - Heated Seat Element - Passenger Back (KA1) 3 - Seat Back Cushion Pad - Passenger 4 - Seat Belt Switch - Passenger 5 - Seat Horizontal Motor - Passenger (1LZ) 6 - Seat Rear Vertical Motor - Passenger (1LZ) 7 - Heated Seat Control Module - Passenger (KA1) 8 - Seat Front Vertical Motor - Passenger (1LZ) 9 - Heated Seat Switch - Passenger (KA1) 10 - Seat Adjuster Switch - Passenger (1LZ) 11 - Inflatable Restraint Front Passenger Presence System (PPS) Module 12 - Seat Cushion - Passenger 13 - Heated Seat Element - Passenger Cushion (KA1) 14 - Seat Cover - Passenger Service and Repair Windshield Washer Spray Nozzle: Service and Repair Windshield Washer Nozzle Replacement Page 3957 6. Remove the remaining oil pan bolts and the oil pan. 7. Remove the oil pan gasket. 8. Remove all traces of the old gasket material. Clean the transaxle case and oil pan gasket surfaces with solvent, and allow to air dry. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the oil pan gasket, the oil pan, and hand start the oil pan bolts. Tighten the oil pan bolts to 12 Nm (9 lb ft). 2. Lower the vehicle. 3. Refill the transaxle using DEXRON(R) VI fluid to the specified refill capacity. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Symptom Related Diagnostic Procedures/4T45-E - Automatic Transmission/Transmission Fluid Level and Condition Check). * The bottom pan removal capacity is approximately 6.5 L (6.9 qt). * The complete overhaul capacity is approximately 9 L (9.5 qt). * The dry capacity is approximately 12.2 L (12.9 qt). Page 1435 Fuse Block: Removal and Replacement Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Rear Electrical Center or Junction Block Replacement Rear Electrical Center or Junction Block Replacement Page 9251 The primary exterior body paint codes on the SPID label may be missing on some 2010 vehicles. Above is a chart with the primary exterior body colors for your reference. Disclaimer Page 4378 10. Place a brass drift against the CV joint cage (1). 11. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 12. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 13. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 14. Repeat this process to remove all 6 of the balls. 15. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (2). At the same time, align the cage windows (3) with the lands of the outer race. 16. Lift out the cage (4) and the inner race. Page 4046 Page 1765 10. To release the tensioner apply a counterclockwise rotational torque to the crankshaft balancer bolt of 45 Nm (33 lb ft). 11. Remove the EN-48953 - retention tool (1). 12. Install the upper timing chain guide and bolts and tighten to 10 Nm (89 lb in). 13. Install the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). 14. Install the camshaft cover. Refer to Camshaft Cover Replacement (See: Cylinder Head Assembly/Valve Cover/Service and Repair). Audio - Buzz Noise When Using Bluetooth(R) Cellular Phone Microphone: Customer Interest Audio - Buzz Noise When Using Bluetooth(R) TECHNICAL Bulletin No.: 10-08-44-003B Date: October 13, 2010 Subject: Buzz Noise During Call When Using Bluetooth(R) (Replace Microphone and Bezel) Models: 2009-2011 Buick Enclave, LaCrosse, Lucerne 2008-2011 Cadillac CTS, CTS-V 2009-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT, SRX, STS (with RPO YQ1 or YQ2), XLR 2009-2010 Chevrolet Cobalt, Corvette, Equinox, HHR, Impala, Malibu, Silverado, Suburban, Tahoe, TrailBlazer, Traverse 2010-2011 Chevrolet Camaro 2009-2010 GMC Envoy 2009-2011 GMC Acadia, Sierra, Yukon, Yukon XL 2009-2010 Pontiac G5, G6, Solstice, Torrent 2009-2010 HUMMER H2, H3 2009-2010 Saturn AURA, OUTLOOK, SKY, VUE 2009 Saab 9-7X All Equipped with OnStar(R) (UE1) and Bluetooth (UPF) Supercede: This bulletin is being revised to replace the microphone and bezel (if needed) and update model years. Please discard Corporate Bulletin Number 10-08-44-003A (Section 08 - Body and Accessories). Condition Some customers may comment on a buzz noise (from the land-line side only) during a call. On any vehicle equipped with OnStar(R) (UE1) and Bluetooth(R) (UPF), an electromagnetic compatibility (EMC) buzz can be heard from the land-line side only of the phone during a Bluetooth(R) phone call made with an older model global system for mobile communications (GSM) phone. The buzz is only heard with older model GSM phones and is dependent on the distance of the phone from the microphone. The newer 3G GSM phones or other cellular phones (CDMA, TDMA, etc.) have not shown this concern. Correction Equipped with Headliner Microphone (Cobalt, HHR (non-sunroof) H2, H3) A new microphone and bezel has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Also replace the bezel. Refer to the parts information table below for correct color/part number. Equipped with Overhead Console Microphone Page 8118 Seat Occupant Sensor: Service and Repair Inflatable Restraint Passenger Presence System Replacement - Front Page 2192 18. Remove the thermostat housing bolts. Note: Twist the water transfer pipe while pulling in order to remove it from the water pump. 19. Remove the thermostat from the vehicle. 20. Remove the water transfer pipe from the thermostat housing, if necessary. 21. Remove and discard the water transfer pipe O-ring seals, if necessary. 22. Remove the thermostat cover bolts and cover, if necessary. 23. Remove the thermostat, if necessary. 24. Remove and discard the thermostat cover O-ring seal, if necessary. 25. Remove all debris and thread sealant from the engine coolant temperature (ECT) sensor and bolt holes if the housing is being re-used. Installation Procedure Page 712 Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Page 5813 Ensure that the appropriate wire colors match up (as noted in Step 4) when the connection is made between the seat airbag harness and body harness. 10. Slide all four terminals (2) into the appropriate connector body as shown above. Install the blue terminal position assurance (TPA) devices onto the connector ends. 11. Add NyoGel 760 Lubricant (dielectric lubricant), P/N 12377900 (in Canada, use P/N 10953529) (Saturn retailers, use P/N 12345579) to the terminals on both sides of the connections. 12. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the body harness up to the back of the connector. 13. Reinstall the conduit on the seat airbag harness. 14. Repeat the above procedure on the passenger seat. Reinstall Seats 1. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 2. Reconnect the seat to body harness connector and the seat airbag connector. Reroute Harness and Secure Connector Follow the procedure below to re-route and attach the harness connector to the body harness bundle: 1. The original seat airbag connector was attached with a clip to the bottom of the seat (2) as shown above. 2. Using two wire ties, secure the seat airbag connector to the seat wire bundle as shown. Ensure that there is enough slack for full range of motion of the seat. 3. Inspect the wires through the full range of motion of the seat again as in Step 2. Ensure that the wires have been secured in an orientation that allows full seat motion with adequate clearance to the connectors and sufficient slack in the wires. 4. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 5. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Diagrams Horn Switch: Diagrams Component Connector End Views Horn Switch Page 3975 Fluid Pump: Removal and Replacement Auxiliary Fluid Pump Control Module Replacement Auxiliary Fluid Pump Control Module Replacement Auxiliary Fluid Pump Inlet Pipe Replacement Auxiliary Fluid Pump Inlet Pipe Replacement Page 9558 4. View of the female half of the connector with male terminals. 5. Use the J 38125-215 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 6. View of the female half of the connector with male terminals. Page 1617 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Page 5159 Page 588 Brake Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Brake Master Cylinder Pressure Sensor (LAT) Page 7287 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Coolant Heater Replacement Engine Block Heater: Service and Repair Coolant Heater Replacement Coolant Heater Replacement Removal Procedure 1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). 2. Disconnect the coolant heater cord. 3. Remove the coolant heater bolt. 4. Remove the coolant heater. Installation Procedure Page 7801 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the SIR circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Windshield Wiper Motor Replacement Wiper Motor: Service and Repair Windshield Wiper Motor Replacement Windshield Wiper Motor Replacement Page 9191 crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. Page 4231 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Page 9173 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 1110 Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if equipped. Torque Steer Description Torque Steer Description A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration. The following factors may cause torque steer to be more apparent on a particular vehicle: * A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front tires for differences in the brand, the construction, or the size. If the tires appear to be similar, change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. * A large difference in the right and left front tire pressure * Left-to-right differences in the front view axle angle may cause significant steering pull in a vehicle. The pull will be to the side with the most downward sloping axle from the differential to the wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to level ground may be used as an indication of bias axle angles. The side with the higher transaxle pan (shown on the left side of the illustration) has the most downward sloping axle angle. Memory Steer Description Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander Description Service and Repair Service Port HVAC: Service and Repair Air Conditioning Refrigerant Service Valve Core Replacement Special Tools * J 39400-A Halogen Leak Detector * J 46246 Valve Core Removal Tool Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 2. Remove the service port valve core using J 46246 or equivalent. Installation Procedure Page 4676 10. Disconnect the master cylinder secondary brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and contamination. 11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 12. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 13. Remove the 3 BPMV bracket nuts (1). 14. Remove the BPMV and bracket assembly. Page 5415 Digital Video Disc (DVD) Control Module X4 (SPO Accessory) (UJ5) Page 1413 Page 8966 Second Design - Black Painted (DO NOT Lube) Hydraulic Assist Power Steering First Design - Bare Steel Tube (Lube OK) Second Design - Black Painted (DO NOT Lube) In the unlikely event that the source of the noise is identified as a second design shaft with black painted tube, it must be replaced. Correction 1 (Only for First Design - DO NOT USE FOR 2ND DESIGN) Lubricate the intermediate shaft with steering column shaft lubrication kit, P/N 26098237. 1. From inside the vehicle, remove the instrument panel insulator panel - left side panel to gain access to the intermediate shaft. 2. Remove the intermediate shaft to steering column attachment bolt. 3. Remove the intermediate shaft from the steering column. 4. Extend the intermediate shaft all the way. Using the intermediate shaft grease kit, P/N 26098237, inject the grease into the gap between the inner shaft and the outer shaft as you are collapsing the shaft. This will draw the grease into the shaft. 5. Cycle the shaft up and down several times to distribute the grease. Important Remove original thread locker material from the bolt and apply Loctite(R) 242 (or equivalent) to the threads of the bolt and reinstall intermediate shaft bolt. 6. Install the intermediate shaft to the column. Tighten - For electronic power steering, tighten the bolt to 49 Nm (36 lb ft). - For hydraulic power steering, tighten the bolt to 62 Nm (46 lb ft). Specifications Firing Order: Specifications Ignition System Specifications Page 7143 Stabilizer Link: Service and Repair Stabilizer Shaft Link Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Disconnect the stabilizer link from the stabilizer shaft. 4. Disconnect the stabilizer link from the strut assembly and remove from the vehicle. Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Page 468 Page 2992 Disclaimer Page 2837 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Page 9471 Page 4073 2. Install the TFP switch assembly onto the control valve body assembly and install the bolts. Tighten the control valve body bolts to 12 Nm (9 lb ft). 3. Install the transaxle case side cover. 4. Start the engine, warm up the transaxle, and check for leaks. 5. Inspect for proper fluid level. Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 6. Reset the TAP values. Refer to Transmission Adaptive Functions See: Description and Operation. Page 7255 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Page 6493 Page 2194 9. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring. 10. Position the thermostat housing against the engine. 11. Install the thermostat housing bolts and tighten to 10 Nm (89 lb in). 12. If reinstalling the old sensor, coat the threads with sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). 13. Install the ECT sensor, if necessary. Tighten the sensor to 20 Nm (15 lb ft). 14. Lower the vehicle. 15. Install the heater inlet hose (3) to the thermostat housing. 16. Position the heater inlet hose clamp at the thermostat housing. 17. Install the auxiliary heater water pump hose (2) to the thermostat housing. 18. Position the auxiliary heater water pump hose clamp at the thermostat housing. 19. Install the auxiliary heater water pump hose clip (1) to the heater outlet hose. Page 6868 From the technicians point of view of the BACK of the sensor (2), the connector will be on your left. 2. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 3. Install the connector to the sensor. 4. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (4) * A pin hole (7) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (6) * An alignment mark (5) for installation 5. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * A foam ring (3) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly * A view of the inside of the connector Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 6. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 7. Install the connector to the sensor. 8. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A raised rotor flange cuff (5) * An alignment mark (4) for installation 9. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. Page 6989 8. Install the three pieces of foam to the attaching bracket starting at the top center inside the bracket and proceed down across the fuel lines, then at the inside of the bracket at the left and right positions of the center piece of foam. Finally, install the last two pieces of foam to the inside bracket at the left and right extended sides behind the retaining holes as shown above. 9. Reposition the radiator surge tank back onto the bracket and seat the two retaining tabs on the tank. 10. Drive the vehicle to verify that the noise is no longer present. Parts Information Order Adhesive Back Shim Stock from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 825 * We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information This product is current available from Kent Industries (1-888-YES-KENT). Warranty Information For vehicles repaired under warranty, use the table. Disclaimer 6T30/6T40/6T45 - Automatic Transmission Shift Solenoid: Specifications 6T30/6T40/6T45 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Locations Wiper Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 9193 same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Locations Throttle Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left Side of the Instrument Panel Components (1 of 2) 1 - Brake Pedal Position (BPP) Sensor 2 - Accelerator Pedal Position (APP) Sensor 3 - Accelerator Pedal 4 - Brake Pedal Page 2687 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LAT or LE5 or LE9) Engine Coolant Temperature (ECT) Sensor (LY7) Page 3432 10. Install the engine wiring harness clips (1) to the fuel rail tabs (2). 11. Connect the fuel injector wiring harness electrical (1) to the MAP sensor. Page 9652 6. Release the rear lower half of the wire dress cover. 7. Release the tabs that are holding the wire dress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Page 3214 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH8) Page 1735 Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust (LY7) Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake (LY7) Page 8535 Page 2514 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). 6. Remove the alignment tool. Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 7. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Page 5073 17. Remove the battery tray bolts (1), nut (2), and battery tray (3). Installation Procedure Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Set the battery tray (3) into position and install the bolts (1), and nut (2). Tighten the bolts to 25 Nm (18 lb ft). Page 4102 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual Valve Disassembled Views Disassembled Views Case and Associated Parts Page 3221 4. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 5. Install the shift control cable to transaxle range switch lever and verify proper operation. Page 6447 Wheel Speed Sensor (WSS) - Right Rear Window Motor - Driver (AXG or LTZ) Page 6708 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. * For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. * For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Page 9430 Rear Seat Back Side Cushion Cover Replacement Rear Seat Back Side Cushion Cover Replacement Page 7652 3. Install the heater outlet hose to the heater core. 4. Reposition the heater outlet hose clamp at the heater core using the J 38185. 5. Install the surge tank to the surge tank bracket. 6. Fill the coolant. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). Page 6062 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Specifications Brake Fluid: Specifications Hydraulic Brake System: DOT 3 Hydraulic Brake Fluid (GM Part No. U.S. 88862806, in Canada 88862807). Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 9533 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Page 2391 4T45-E - Automatic Transmission Shift Solenoid: Service and Repair 4T45-E - Automatic Transmission 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. 2. Remove the 1-2 shift solenoid retainer clip (304), the 1-2 shift solenoid (305) with O-ring (303), the 1-2 shift valve (302), and the 1-2 shift valve spring (301). Installation Procedure 1. Install the 1-2 shift valve spring (301), the 1-2 shift valve (302), the 1-2 shift solenoid (305) with O-ring (303) and the 1-2 shift solenoid retainer clip (304). 2. Install the transmission side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions See: Automatic Transmission/Transaxle/Description and Operation. 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of Page 6167 Fuse Block - Underhood X3 Page 5169 Page 4993 Lateral Accelerometer: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Page 10603 1. Install the power window motor bolts to the window regulator and tighten to 6 Nm (53 lb in). 2. Install the window regulator and motor through the access opening. 3. Install the front door window regulator. Refer to Front Side Door Window Regulator Replacement (See: Service and Repair/Removal and Replacement/Front Side Door Window Regulator Replacement). 4. Connect the electrical connector (2) to the power window motor. 5. Remove the masking tape. Lower the window far enough in order to gain access to the bolts (1, 2) that attach the window to the regulator. 6. Install the bolts (1, 2) that attach the window to the regulator and tighten to 10 Nm (89 lb in). 7. Inspect the window for proper operation. 8. Install the front door water deflector. Refer to Front Side Door Water Deflector Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Side Door Water Deflector Replacement). 9. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Side Door Trim Panel Replacement). Page 6825 1. Ensure that the steering wheel is set in a straight ahead position. 2. Center the steering wheel position sensor prior to alignment. Refer to Steering Wheel Position Sensor Centering (See: Sensors and Switches Steering and Suspension/Sensors and Switches - Steering/Steering Angle Sensor/Service and Repair/Steering Wheel Position Sensor Centering) 3. Loosen the tie rod jam nut (5). 4. Adjust the toe to specification by turning the adjuster (6). Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the tie rod jam nut (5) to 68 Nm (50 lb ft). Rear Camber Adjustment Rear Camber Adjustment 1. Loosen the inner lower control arm cam bolt nuts. 2. Rotate the cam bolts to the required camber specification setting. Refer to Wheel Alignment Measurement (See: Wheel Alignment Measurement ). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Maintain the camber setting while tightening the cam bolt nuts. Tighten the inner lower control arm (front) bolt nut to 110 Nm (81 lb ft). Note: Check the toe setting AFTER changing camber or caster. 4. Check the camber setting after tightening. Page 9623 Page 6824 2. File the lower hole until the outer flange slot matches the inner flange slot. 3. Connect the strut to the knuckle. Refer to Strut Assembly Replacement (See: Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Strut/Strut Assembly Replacement). 4. Adjust the camber to specification by moving the top of the wheel in or out. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the strut to knuckle nuts. Tighten the nuts to 120 Nm (89 lb ft). Front Caster Adjustment Front Caster Adjustment The front caster is not adjustable. If the front caster angle is not within specifications, inspect for suspension support misalignment or front suspension damage. Replace any damaged suspension components as necessary. Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment Page 8633 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 1327 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Place a drain pan under the oil drain plug. 3. Remove the oil pan drain plug. 4. Allow the oil to drain completely. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the oil pan drain plug and tighten to 25 Nm (18 lb ft). 6. Lower the vehicle. Note: DO NOT use an open end wrench on the hex on top of the oil filter cap. 7. use an oil filter wrench on the outside diameter of the oil filter cap. 8. Remove the oil filter cap and filter. 9. Remove the filter from the cap. Installation Procedure Page 9681 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Page 5017 Yaw Rate Sensor: Diagrams Component Connector End Views Yaw and Lateral Accelerometer Sensor Page 243 Fuse Block - Rear X1 Page 9135 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to auto range to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Page 6774 6. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals on to the bare wire using the J38125-7 crimp tool, jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 7. Position the wire seal to the terminal and crimp the seal and insulation using the J-38125-6 crimp tool, jaw 1 (1). The completed terminal and seal should appear as shown above (body harness connector shown). Note Avoid getting solder on the terminal end or overheating the terminal. Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. 8. Solder all four terminals at the wire crimp. 9. Slide the two body harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Page 4514 Transmission Speed Sensor: Service and Repair 6T70/6T75 - Automatic Transmission Output Speed Sensor Replacement Output Speed Sensor Replacement Input Speed Sensor Replacement Input Speed Sensor Replacement Page 6642 Ensure that the appropriate wire colors match up (as noted in Step 4) when the connection is made between the seat airbag harness and body harness. 10. Slide all four terminals (2) into the appropriate connector body as shown above. Install the blue terminal position assurance (TPA) devices onto the connector ends. 11. Add NyoGel 760 Lubricant (dielectric lubricant), P/N 12377900 (in Canada, use P/N 10953529) (Saturn retailers, use P/N 12345579) to the terminals on both sides of the connections. 12. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the body harness up to the back of the connector. 13. Reinstall the conduit on the seat airbag harness. 14. Repeat the above procedure on the passenger seat. Reinstall Seats 1. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 2. Reconnect the seat to body harness connector and the seat airbag connector. Reroute Harness and Secure Connector Follow the procedure below to re-route and attach the harness connector to the body harness bundle: 1. The original seat airbag connector was attached with a clip to the bottom of the seat (2) as shown above. 2. Using two wire ties, secure the seat airbag connector to the seat wire bundle as shown. Ensure that there is enough slack for full range of motion of the seat. 3. Inspect the wires through the full range of motion of the seat again as in Step 2. Ensure that the wires have been secured in an orientation that allows full seat motion with adequate clearance to the connectors and sufficient slack in the wires. 4. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 5. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Page 6273 Page 5541 Main Contactor Relay (HP7) X2 Main Contactor Relay (HP7) X3 Manifold Absolute Pressure (MAP) Sensor (LAT or LE5 or LE9) Page 859 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Page 10205 Dimmer Switch: Service and Repair Instrument Panel Lamp Dimmer Switch Replacement Page 5160 Page 8321 Communications Control Module: Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 5024 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (LAT or LE5 or LY7 or LE9) Page 5454 Page 8117 Seat Occupant Sensor: Locations Passenger Compartment/Roof Component Views Seat Components - Passenger 1 - Seat Back Cover - Passenger 2 - Heated Seat Element - Passenger Back (KA1) 3 - Seat Back Cushion Pad - Passenger 4 - Seat Belt Switch - Passenger 5 - Seat Horizontal Motor - Passenger (1LZ) 6 - Seat Rear Vertical Motor - Passenger (1LZ) 7 - Heated Seat Control Module - Passenger (KA1) 8 - Seat Front Vertical Motor - Passenger (1LZ) 9 - Heated Seat Switch - Passenger (KA1) 10 - Seat Adjuster Switch - Passenger (1LZ) 11 - Inflatable Restraint Front Passenger Presence System (PPS) Module 12 - Seat Cushion - Passenger 13 - Heated Seat Element - Passenger Cushion (KA1) 14 - Seat Cover - Passenger Page 7117 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Page 8615 Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3 or HP7) Locations Electronic Brake Control Module: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 2377 Locations Transmission Position Switch/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components (ME7 or MN5) 1 - Park/Neutral Position (PNP) Switch Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) Page 9138 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Switch Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the oil pressure switch. 3. Remove the engine oil pressure switch. Installation Procedure Page 9655 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 1734 Variable Valve Timing Solenoid: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust (LY7) Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake (LY7) Page 9735 Page 6341 Ignition Coil 2 (LAT or LE5 or LE9) Page 6040 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Glass/Body - Windshield Wiper Performance Windshield: All Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Page 50 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Locations Seat Heater Control Module: Locations Passenger Compartment/Roof Component Views Seat Components - Driver 1 - Seat Back Cover - Driver 2 - Heated Seat Element - Driver Back (KA1) 3 - Seat Back Cushion Pad - Driver 4 - Seat Recline Motor - Driver (1LZ) 5 - Seat Horizontal Motor - Driver (AG1 or 1LZ) 6 - Seat Rear Vertical Motor - Driver (AG1 or 1LZ) 7 - Heated Seat Control Module - Driver (KA1) 8 Seat Front Vertical Motor - Driver (AG1 or 1LZ) 9 - Seat Recline Switch - Driver (1LZ) 10 - Seat Adjuster Switch - Driver 11 - Seat Belt Switch - Driver 12 - Seat Cushion - Driver 13 - Heated Seat Element - Driver Cushion (KA1) 14 - Seat Cover - Driver Passenger Compartment/Roof Component Views Page 9186 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 6476 Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (ME7 or MN5) Page 6528 X412 Inline Harness Connector End Views X412 Body Harness to the Right Roof Rail Jumper Harness Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. For example, a failure condition exists if the ECM detects low voltage when the MIL is commanded OFF, or high voltage when the MIL is commanded ON. Reference Information Schematic Reference * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Cluster Schematics) * Engine Controls Schematics (See: Diagrams/Electrical Diagrams/Powertrain Management/System Diagram) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification 1. Ignition ON, command the MIL ON and OFF with a scan tool. The MIL should turn ON and OFF as commanded. 2. Command the MIL ON and OFF with a scan tool while observing the following control circuit status parameters: * MIL Ckt. Short Gnd Test Status * MIL Ckt. Open Test Status * MIL Ckt. Short Volts Test Status Each parameter should change from OK and Not Run or from Not Run and OK. 3. Operate the vehicle within the Conditions for Running the DTC to verify that the DTC does not reset. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing 1. Ignition ON, verify that the instrument panel cluster (IPC) warning indicators are illuminated. ‹› If the IPC warning indicators are not illuminated, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 2. Ignition OFF, disconnect ECM X1 harness connector. Ignition ON, the MIL should not illuminate. Page 1050 1. Install the 3 input speed sensor seals (1). 2. Install the input speed sensor (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the input speed sensor bolt (2) M6 x 23 and tighten to 12 Nm (106 lb in). 4. Connect the input speed sensor electrical connector (1). 5. Install the transmission control valve body cover. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning/6T30/6T40/6T45 - Automatic Transmission). Page 9431 Rear Seat Back Cushion Replacement Rear Seat Back Cushion Replacement Page 6452 Window Switch - Left Rear Page 3220 Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 8. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. Page 9482 Page 3936 Transmission Fluid Cooler Pipe Connector Replacement - Radiator Transmission Fluid Cooler Pipe Connector Replacement - Radiator Removal Procedure 1. Drain the cooling system. 2. Remove the transaxle oil cooler hoses from the oil cooler fittings on the radiator. Refer to Transmission Fluid Cooler Hose Replacement (See: Transmission Fluid Cooler Hose Replacement). Note: Do not remove the upper and lower transaxle oil cooler fittings from the radiator at the same time other wise the transaxle oil cooler will fall inside the radiator end tank. 3. Remove the oil cooler fitting from the radiator. Installation Procedure 1. Inspect the new O-ring seals for cracks, cuts or damage. Replace if necessary. Page 803 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position (CKP) system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * CKP sensor replacement * Any engine repairs which disturb the crankshaft to CKP sensor relationship Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the CKP system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensor activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the CKP system variation learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicle's transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 7961 8. Position the wire seal to the terminal and crimp the seal and insulation using the J38125-6 crimp tool, Jaw 1 (1). Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. Note Avoid getting solder on the terminal end or overheating the terminal. 9. Solder all four terminals at the wire crimp. 10. Slide the two seat airbag harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Ensure that the appropriate wire colors match up (as noted in NOTE above Step 4) when the connection is made between the seat airbag harness and body harness. 11. Slide all four terminals (2) into the appropriate connector body as shown in the illustration. Install the blue terminal position assurance (TPA) devices onto the connector ends. 12. Install the gray connector clip onto the appropriate connector body. 13. Add NyoGel 760 lubricant (dielectric lubricant) to the terminals on both sides of the connections. 14. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the seat harness for a length of 30 mm (1.2 in) from the back of the connector. Continue to wrap the tape around the back of the connector. 15. Slide the conduit back up. Wrap tape starting at the back of the connector and over the conduit for a length of 130 mm (5 in). 16. Tape on the gray clip at 110 mm (4.33 in) from the back of the connector. Note that the clip orientation should be in line with the retainer clip orientation on the connector. 17. Repeat the above procedure on the passenger seat. Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. Page 5470 Fuel Injector 3 (LAT or LE5 or LE9) Fuel Injector 3 (LY7) Page 10002 Page 9318 Sun Shade: Service and Repair Sunroof Sunshade Replacement Sunroof Sunshade Replacement Removal Procedure Note: Use caution NOT to loosen the center fastener for the water gutter. If the fastener unhooks, it will be necessary to remove the dome lamp to gain access to the water gutter hole to reinstall the retainer. If equipped. 1. Remove the sunroof window panel from the sunroof module. Refer to Sunroof Window Replacement (See: Sunroof / Moonroof Panel/Service and Repair). 2. Remove the sunroof sunshade (7) from the module. 3. Do the following from the right side and through the sunroof opening, outside the vehicle: 1. Close the sunshade to with in an inch of the front opening. 2. Carefully arch the rear center of the sunshade. 3. Pull upward in the rear center of the sunshade (7). 4. Release the tabs (5, 6) from under the water gutter. 5. Lift upward in the rear center of the sunshade until the guide tabs (3) release from the track. 6. Slightly rotate the sunshade clockwise at the same time push forward releasing (4, 2) and then (1). Page 6698 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 9530 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 2832 Page 9645 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Page 7134 8. Install the three pieces of foam to the attaching bracket starting at the top center inside the bracket and proceed down across the fuel lines, then at the inside of the bracket at the left and right positions of the center piece of foam. Finally, install the last two pieces of foam to the inside bracket at the left and right extended sides behind the retaining holes as shown above. 9. Reposition the radiator surge tank back onto the bracket and seat the two retaining tabs on the tank. 10. Drive the vehicle to verify that the noise is no longer present. Parts Information Order Adhesive Back Shim Stock from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 4664 Page 1485 ‹› If the MIL is illuminated, test the MIL control circuit terminal listed below for a short to ground. If the circuit tests normal, replace the IPC. * ECM terminal X1-27 for RPO LE5 * ECM terminal X1-12 for RPO LAT 3. Ignition ON, connect a 3A fused jumper wire between the MIL control circuit terminal listed below and ground. The MIL should illuminate. * ECM terminal X1-27 for RPO LE5 * ECM terminal X1-12 for RPO LAT ‹› If the MIL does not illuminate, test the MIL control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the IPC/bulb. 4. If all circuits/connections test normal, replace the ECM. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Instrument Cluster Replacement (See: Instrument Panel, Gauges and Warning Indicators/Compass/Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement. setup, and programming Page 6457 Yaw and Lateral Accelerometer Sensor Page 9142 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Page 7112 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become UN-centered and cause possible damage to the SIR coil. If you think the SIR coil has became UN-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Page 3543 1. Install the ignition coil(s). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ignition coil bolt(s) and tighten to 10 Nm (89 lb in). 3. Connect the engine wiring harness electrical connector(s) (1) to the ignition coil(s) (2). 4. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 5364 Fuse Block: Removal and Replacement Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement Rear Electrical Center or Junction Block Replacement Rear Electrical Center or Junction Block Replacement Brake Rotor Assembled Lateral Runout Correction Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction Brake Rotor Assembled Lateral Runout Correction Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications. Determine which method to use for the specific vehicle being repaired. * The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. Refer to Brake Rotor Assembled Lateral Runout Correction - Indexing (See: Brake Rotor Assembled Lateral Runout Correction - Indexing). * The correction plate method of correcting assembled LRO involves the addition of a tapered plate between the brake rotor and the hub/axle flange. The correction plate method can be used to correct LRO that exceeds the specification by up to 0.23 mm (0.009 in). Refer to Brake Rotor Assembled Lateral Runout Correction - Correction Plates (See: Brake Rotor Assembled Lateral Runout Correction - Correction Plates). * The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe (See: Brake Rotor Assembled Lateral Runout Correction On Vehicle Lathe). If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Page 2119 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LAT or LE5 or LE9) Engine Coolant Temperature (ECT) Sensor (LY7) Page 9584 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 1279 9. Install the engine lift bracket (2) and bolts (1). Tighten the bolts to 50 Nm (37 lb ft). 10. Clean any excess power steering fluid from the vehicle and remove the drain pans. 11. Install the drive belt idler pulley. Refer to Drive Belt Idler Pulley Replacement (). 12. Install the power steering pump pulley. Refer to Power Steering Pump Pulley Replacement (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering Pump Pulley Replacement). 13. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair). Page 9594 Page 8093 Note: When the seat belt retractor pretensioner deploys, the deployment fixture may jump about 30 cm (1 ft) vertically. This is a normal reaction of the seat belt pretensioner due to the force of the rapid expansion of gas inside the pretensioner. 18. Place a 12 V minimum/2 A minimum power source, such as a vehicle battery, near the shorted end of the harness. 19. Connect the SIR deployment harness wires to the power source. Seat belt pretensioner deployment will occur when contact is made. 20. Disconnect the SIR deployment harness from the power source after the seat belt retractor pretensioner deploys. 21. Seat one banana plug into the other in order to short the deployment harness leads. 22. If the seat belt retractor pretensioner did not deploy, disconnect the adapter and discontinue the procedure. Contact the Technical Assistance Group. Otherwise, proceed to the following steps. 23. Put on a pair of shop gloves. 24. Disconnect the pigtail adapter from the seat belt retractor pretensioner as soon as possible. 25. Dispose of the deployed seat belt retractor pretensioner through normal refuse channels. 26. Wash hands with a mild soap. Page 5254 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools Page 5018 Yaw Rate Sensor: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Page 2063 * Worn ignition wires * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Page 9061 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Page 2303 Page 1598 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4 in) should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Page 5762 Locations Transmission Temperature Sensor/Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Fuel Pressure Gauge Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gauge Installation and Removal Fuel Pressure Gauge Installation and Removal Special Tools CH-48027-100 - Digital Pressure Gauge For equivalent regional tools, refer to Special Tools (See: Computers and Control Systems/Tools and Equipment). Installation Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). 2. Connect the CH-48027-1 - gauge (1) to the CH-48027-2 - adapter (2). 3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027-100 - gauge, refer to the manufacture's directions. Removal Procedure Page 10119 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools Page 8679 1. Prepare all mating surfaces as necessary. 2. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces. Note: Verify the location of the front rail using 3-dimensional measuring equipment. 3. Position the impact bar bracket on the rail and clamp in place. Page 9731 Heated Seat Control Module - Driver X3 (KA1) Page 1466 Fuse Block - Rear X4 Page 3076 4. Disconnect the engine wiring harness electrical connectors (2) from the ECM. 5. Remove the engine wiring harness clips (3) from the ECM bracket (4). Caution: Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables or when charging the vehicles battery. 6. Gently lift the ECM retainers (1) up, disengaging the retainers from the ECM (2). 7. Tilt the ECM towards the engine and remove the ECM (2) from the bracket. Installation Procedure Page 4863 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 6319 Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 (LY7 or LZ4 or LZE) Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 2 (LY7 or LZ4 or LZE) Page 3790 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Remove the automatic transaxle control assembly. 2. Disconnect the Shift Lock Control Solenoid connector from the solenoid. 3. Using a flat-blade screwdriver or similar tool pry the solenoid off of the ball-sockets on the solenoid plunger and solenoid body. Page 5358 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Luggage Compartment/Rear of Vehicle Component Views Left Side of the Luggage Compartment Components Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Page 86 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 9469 Page 5328 Page 4846 6. Remove the piston dust boot seal (2) from the seal counterbore in the caliper and discard the dust boot seal. 7. Using a small wooden or plastic tool, remove the piston seal from the caliper bore and discard the piston seal. 8. Inspect the operation of the integral park brake mechanism. Rotate the park brake lever back and forth while observing the movement of the park brake mechanism actuator assembly in the caliper bore. Note: The park brake lever, lever return spring and actuator shaft seal are not serviceable components of the integral park brake mechanism. Do not disassemble the integral park brake mechanism. 9. If the integral park brake mechanism was not operating properly (binding or seized), replace the brake caliper assembly. Installation Procedure Note: Do not use abrasives to clean the brake caliper piston. 1. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 2. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 3. Clean the brake caliper piston bore and seal counterbore, the caliper piston, and the caliper sleeves with denatured alcohol, or equivalent. 4. Dry the caliper piston bore and counterbore, the piston, and the sleeves with non-lubricated, filtered air. 5. Inspect the caliper piston for cracks, scoring, damage to the chrome plating, and/or damage to the integral adjusting mechanism. Replace the caliper piston if any of these conditions exist. 6. Inspect the caliper mounting holes for cracks, scoring, pitting, rust, and/or excessive corrosion. Replace the caliper assembly if any of these conditions exist. 7. Lubricate the new piston seal with GM approved or equivalent brake fluid from a clean, sealed brake fluid container. 8. Install the lubricated, new piston seal into the caliper bore. Page 3676 Transmission Control Module (TCM) (MN5 with LZ4 or LZE) Page 8868 Page 6915 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Connect the power steering gear inlet hose (2) and power steering gear outlet hose (4) to the steering gear (3) and install the power steering gear inlet hose bolt (1). Prior to tightening the power steering gear inlet hose bolt (1), rotate the power steering gear outlet hose (4) clockwise/downwards so it touches the power steering gear inlet hose (2). Verify the power steering hoses are still touching after the power steering gear inlet hose bolt is tight. Tighten the bolt to 27 Nm (20 lb ft). 6. Install the 2 power steering gear outlet hose retainers to the front of the front frame. Page 10419 Page 9208 Keyless Entry Transmitter: Electrical Diagrams Remote Function Schematics Keyless Entry Garage Door Opener Page 4916 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the rear park brake cable retainer bolt and tighten to 10 Nm (89 lb in). 7. Install the plastic retainer clips (1) to the body, if equipped. 8. Install the plastic retainer clip (2), if equipped. 9. Install the cable to the bracket (1). 10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 11. Lower the vehicle. Page 6325 Heated Seat Control Module - Driver X3 (KA1) Page 7695 10. Remove the HVAC module assembly mounting bolts from the instrument panel reinforcement. 11. Remove the HVAC module assembly to dash panel bolts (1). Page 6168 Page 5754 Relay Box: Locations Fuse Block - Rear Electrical Center Identification Views Fuse Block - Rear Label Page 2487 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Lower Front and Rear of the Engine Components - Oxygen Sensors (LY7) Page 1053 Input Speed Sensor Seal Replacement Page 5437 Engine Control Module (ECM) X1 (LAT) Page 4366 1. Position the cage (2) so that the larger radius corners of the cage windows are up. 2. Position the inner race 90 degrees to the centerline of the cage. 3. Insert the inner race through the bottom of the cage. 4. Align the lands of the inner race with the windows of the cage. 5. Move the inner race land into the cage window. 6. Rotate the inner race down and remove it from the cage. 7. Rotate the inner race within the cage so that the grooved surface of the inner race is facing up. 8. Align the inner race ball bearing tracks with the cage windows. 9. Wrap a clean shop towel around the CV joint outer race splined shaft. 10. Place the outer race vertically in a bench vise. 11. Position the cage (1) and the inner race at 90 degrees to the centerline of the outer race. 12. With the inner race and the cage assembly in a vertical position, insert the cage and the inner race into the outer race. Page 7401 6. Remove the wheel bearing/hub mounting bolts (1). 7. Remove the wheel bearing/hub and backing plate from the steering knuckle. Page 2031 Fuel Pressure: Service Precautions Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Page 8346 Disclaimer Specifications Crankshaft Main Bearing: Specifications Crankshaft Bearings - Lower Crankcase to Block - Bedplate First Pass ............................................................................................................................................. ......................................................... 20 Nm (15 lb ft) Final Pass ........................................................ ..................................................................................................................................................... 70 Degrees Lower Crankcase Perimeter Bolt ......................................................................................................... ......................................................... 25 Nm (18 ln ft) Crankshaft Main Bearing Clearance ............................................................................................................................. 0.031-0.067 mm (0.0012-0.0026 in) Page 2863 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 1064 Window Switch - Left Rear Page 908 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Exhaust Camshaft Position Sensor Replacement - Exhaust Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (5) from the exhaust camshaft position (CMP) sensor (4). 3. Remove the CMP sensor bolt. (Intake CMP shown, exhaust CMP similar). 4. Remove the CMP sensor. Installation Procedure Page 6219 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 6584 Fuse Block - Rear Top View Page 10014 Page 346 Front Suspension Stabilizer Bushing: Service and Repair Front Suspension Stabilizer Shaft Insulator Replacement Removal Procedure Important: The stabilizer shaft insulators and clamps can only be service when the stabilizer shaft is removed from the vehicle. Remove the stabilizer shaft assembly. Refer to Stabilizer Shaft Replacement (See: Service and Repair/Front Suspension). Installation Procedure Important: The installation of the insulators, clamps and bolts and torque specifications reside in the stabilizer shaft replacement procedure. Install the stabilizer shaft assembly. Refer to Stabilizer Shaft Replacement (See: Service and Repair/Front Suspension). Page 3806 1 - Control Valve Body Cover Assembly 2 - Transmission Fluid Level Indicator Assembly 3 - Fluid Level Indicator Tube - Model Dependent 4 - Fluid Level Indicator Tube Seal - Model Dependent 5 Control Valve Body Cover Assembly Gasket 6 - Control Valve Body Cover Stud 7 - Control Valve Body Cover Bolt 8 - Control Valve Body Bolt 9 - Control Valve Body Bolt 10 - Control Valve Body Cover Wiring Connector Hole Seal 11 - Control Solenoid Valve Spring 12 - Control Valve Body Bolt 13 - Control Valve Body Bolt 14 - Control Valve Body Bolt 15 - Control Solenoid (w/Body and TCM) Valve Assembly 16 - Control Solenoid (w/Body and TCM) Filter Plate Assembly 17 - Manual Shaft Detent Assembly 18 - Control Valve Body Assembly 19 - A/Trans Output Speed Sensor Assembly 20 - A/Trans Output Speed Sensor Bolt 21 - A/Trans Case Assembly 22 - Torque Converter Housing Outer Seal 23 - Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly 24 Front Differential Drive Pinion Gear Lube Tube Page 4790 6. Install the remaining CH-45101-100 - Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the CH-39544-KIT - Complete Torque Socket Set - 10 PCS, or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmarks the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Page 793 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LAT or LE5 or LE9) Engine Coolant Temperature (ECT) Sensor (LY7) Page 9626 Page 6956 21. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (3) * A pin hole (1) for the centering pin-Note the location of the pin hole. * An alignment mark (2) on the flush rotor flange cuff for installation 22. Remove the connector from the sensor. 23. Remove the sensor from the adapter and bearing assembly. 24. To install the sensor, proceed to step 16 in the installation procedure. 25. From the technicians point of view, the FRONT of the sensor will have: * A flush rotor flange cuff (4) * A pin hole (2) for the centering pin-Note the location of the pin hole. * An alignment mark (3) on the flush rotor flange cuff for installation * A foam ring (1) 26. Remove the connector from the sensor. 27. Remove the sensor from the adapter and bearing assembly. 28. To install the sensor, proceed to step 20 in the installation procedure. Installation Procedure Note: If you are reusing the existing sensor, centering of the old sensor is not necessary. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. 1. From the technicians point of view of the FRONT of the sensor (1), the connector will be on your right. Locations Shift Interlock Solenoid: Locations Instrument Panel/Center Console Component Views Center Console Components 1 - Automatic Transmission Shift Lock Control Solenoid 2 - Automatic Transmission Shift Lever Position Indicator Page 3700 Transmission Mode Switch: Service and Repair Manual Shift Auxiliary Position Switch Replacement - Steering Wheel Page 2875 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Page 6039 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 5373 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Page 5252 Page 9145 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Page 9879 Page 1970 Oil Pressure Sender: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (LZ4 or LZE) Engine Oil Pressure (EOP) Switch (LAT or LE5 or LE9) Locations Antenna Control Module: Locations Luggage Compartment/Rear of Vehicle Component Views Rear Window Shelf Components 1 - Cellular (UE1) and Digital Radio Antenna (U2K) 2 - Radio Antenna Module 3 - Remote Start Antenna (AP3) 4 - Speaker - Right Rear 5 - Accessory AC/DC Power Control Module (KV1) 6 Audio Amplifier (UQ3) 7 - Rear Compartment Courtesy Lamp 8 - Remote Control Door Lock Receiver (RCDLR) 9 - Digital Radio Receiver (U2K) 10 - Speaker - Left Rear Page 4674 6. Disconnect the LR brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. 7. Disconnect the rear brake pipe fitting (1). Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and contamination. Page 7080 3. Install the bolts (1) from the trailing arm to the knuckle and tighten to 80 Nm (133 lb ft). 4. Install the mounting bolts for the trailing arm bracket. Tighten the mounting bolts to 60 Nm (44 lb ft). Using the J 45059, rotate the bolt an additional 60 degrees. Page 771 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (LAT or LE5 or LY7 or LE9) Page 5581 Speaker - Left Front Tweeter Speaker - Left Rear (UQA) Page 4486 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (ME7 or MN5) Page 3835 4. Remove the shift lock control solenoid. Installation Procedure 1. Route the shift lock control solenoid through the opening in the front of the control assembly. Page 1284 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Connect the power steering gear inlet hose (2) and power steering gear outlet hose (4) to the steering gear (3) and install the power steering gear inlet hose bolt (1). Prior to tightening the power steering gear inlet hose bolt (1), rotate the power steering gear outlet hose (4) clockwise/downwards so it touches the power steering gear inlet hose (2). Verify the power steering hoses are still touching after the power steering gear inlet hose bolt is tight. Tighten the bolt to 27 Nm (20 lb ft). 6. Install the 2 power steering gear outlet hose retainers to the front of the front frame. Page 9723 Seat Heater: Service and Repair Passenger Seat Cushion Heater Replacement Passenger Seat Cushion Heater Replacement Page 5607 Page 4280 4. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 5. Install the shift control cable to transaxle range switch lever and verify proper operation. Page 2089 7. Remove the radiator surge tank pipe bolts (2). 8. Remove the radiator surge tank pipe from the crossover pipe. 9. Reposition the radiator inlet hose clamp at the crossover pipe. 10. Remove the radiator inlet hose from the crossover pipe. 11. Reposition the thermal bypass hose clamp at the crossover pipe. 12. Remove the thermal bypass hose from the crossover pipe. Page 6247 Digital Video Disc (DVD) Display - Driver Seat Headrest X1 (SPO Accessory) (UJ5) Page 7289 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Page 4388 5. Remove the housing (1) from the tripot joint spider and the halfshaft bar (2). 6. Spread the spacer ring (1) using J 8059 (or equivalent). Page 7668 5. Install the liquid line and compressor hose to the condenser. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Install the liquid line and compressor hose bolt to the condenser and tighten to 20 Nm (15 lb ft). 7. Install the liquid line to the rail clip. Page 1113 The Z height dimension measurement determines the proper ride height for the front end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. Use the following procedure to check the Z height dimension: 1. Using your hands, lift the front bumper approximately 38 mm (1.59 in). 2. Gently remove your hands and allow the vehicle to settle. 3. Repeat the jouncing operation a total of 3 times. 4. You will need 2 measurements to compute the Z height. Measurement 1 should be taken from the bottom edge of the support flange (X) to the ground line. Measurement 2 should be taken from the bottom edge of the lowest point of the ball stud (Y) to the ground line. Subtract measurement 2 (Y) from measurement 1 (X). This will give you your Z height dimension. 5. Using your hands, jounce the front of the vehicle downward approximately 38 mm (1.59 in). 6. Gently remove your hands and allow the vehicle to settle. 7. Repeat the jouncing operation a total of 3 times. 8. Measure the Z height dimension. 9. The true Z height dimension number is the average of the high and the low measurements. Refer to Trim Height Specifications (See: Specifications/Mechanical Specifications/Suspension/System Specifications/Trim Height Specifications). D Height Measurement Page 2355 Engine Control Module (ECM) X2 (LAT) Page 6282 Engine Control Module (ECM) X2 (LZ4 or LZE) Page 9490 Page 7834 Warranty Information (excluding Saab U.S. Models) Important Select the appropriate Labor Operation for the repair that is performed. For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Page 2365 Page 10545 Page 9538 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 3177 Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 (LY7 or LZ4 or LZE) Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 2 (LY7 or LZ4 or LZE) Page 3763 8. Take a CLEAR digital picture of the Tech 2(R) Vehicle Information screen showing the engine Calibration IDs and Verification Numbers as shown above. Retain the printout information and the Tech 2(R) screen photograph with the repair order. Note All pictures must be sent as a.jpg file. 9. E-mail a copy of the picture to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 10. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 11. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Tech 2(R) Displaying All Zeroes for the Verification Numbers on the Calibration ID and Verification Number Screen If the Tech 2(R) that you are using displays all zeroes for the Verification Numbers as shown, then perform the following steps: 1. Update the Tech 2(R) with the latest software from TIS2WEB. 2. Turn OFF the ignition for 90 seconds. 3. Connect the Tech 2(R) to the vehicle. 4. Turn ON the ignition, and build the vehicle. Observe the Tech 2(R) Calibration ID and Verification Number screen for proper operation. ‹› If the Tech 2(R) screen still does not display properly, then turn OFF the ignition for 90 seconds again. Turn ON the ignition and observe the same screen for proper operation. Retrieving Calibrations From a Global A Vehicle This information applies to the 2010 Camaro and is typical of the procedure that will be used on Global A vehicles. 1. Turn OFF the ignition. Page 344 Engine Control Module (ECM) X3 (LAT) Page 7568 HVAC Control Module X2 (C68) Locations Crankshaft Position Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 10016 Locations Intake Air Temperature Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 8203 Page 3020 - Select Fuel Composition Reset (F1). - The first parameter is "Fuel Alcohol Content" displayed as a percentage. If the Fuel Alcohol Content percentage is above 25%, this is the probable cause of DTC P0172. - From this screen the "Fuel Alcohol Content" can be reset to zero by pressing the lower right Tech 2(R) button. It will then display 0% when it's reset. Finally, reprogram the PCM with the latest calibration. This will correct for the PCM alcohol calculations. Note The PCM must be reset from this screen. It does not reset to zero when the PCM is reprogrammed. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 5338 Fuse Block - Underhood X3 Page 8174 Page 5440 Locations Steering Angle Sensor: Locations Steering Column Disassembled View 1 - Intermediate Steering Shaft 2 - Intermediate Steering Shaft Bolt 3 - Steering Wheel Position Sensor 4 - Steering Column 5 - Tilt Lever Spring 6 - Tilt Lever Nut 7 - Tilt Lever Bearing 8 - Tilt Lever Spacer 9 - Tilt Lever Retainer 10 - Tilt Lever Retainer 11 - Tilt Lever Cam 12 - Tilt Lever Follower 13 - Tilt Lever 14 - Tilt Lever Spring 15 - Intermediate Steering Shaft Nut Instrument Panel/Center Console Component Views Behind Left Side of the Instrument Panel Components Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001B Date: January 24, 2011 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2011 Buick Enclave 2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT 2008-2011 Cadillac CTS, CTS-V 2010-2011 Cadillac CTS Sport Wagon, SRX 2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2011 Chevrolet Malibu 2009-2011 Chevrolet Traverse 2010-2011 Chevrolet Equinox 2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2010-2011 GMC Terrain 2006-2010 Pontiac G6 2007-2010 Saturn AURA, OUTLOOK Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Supercede: This bulletin is being revised to update the part number for the recommended splice sleeve. Please discard Corporate Bulletin Number 10-08-42-001A (Section 08 - Body and Accessories). Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 19168446). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (13/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Page 5633 Accessory AC/DC Power Control Module X1 (KV1) Page 6506 X109 Inline Harness Connector End Views X109 Forward Lamp Harness to Left Headlamp Harness Page 2833 Information Bus: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Removal and Replacement Brake Caliper: Removal and Replacement Front Brake Caliper Replacement Front Brake Caliper Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding. 4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 5. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 6. Install and firmly hand tighten 2 wheel nuts to opposite wheel studs in order to retain the rotor to the hub. 7. Install a large C-clamp (1) over the body of the brake caliper (2) with the C-clamp ends against the rear of the caliper body and against the outer brake pad. 8. Tighten the C-clamp until the caliper piston is compressed into the caliper bore enough to allow the caliper to slide past the brake rotor. 9. Remove the C-clamp from the caliper. Page 7283 Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 7011 4. Connect the power steering gear inlet hose and the power steering gear outlet hose to the steering gear. Install the power steering gear inlet hose bolt and tighten to 27 Nm (20 lb ft). 5. Position the transmission rear mount and bracket in place. 6. Install the 3 rear transmission mount bracket nuts and tighten to 50 Nm (37 lb ft). 7. Install the 3 transmission rear mount bolts (1) and tighten to 90 Nm (66 lb ft). 8. Connect the HO2S electrical connector and clip the connector to the rear transmission mount bracket. Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (except LAT) Page 9572 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Page 6018 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Page 5968 Page 10116 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the instructions for Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Staggering the splices by 65 mm (2.5 in) is recommended. Note: Apply the MYLAR tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. * Rewrap the conductors with the MYLAR tape. If the MYLAR tape is damaged, use 3M product AL-36FR to replace the damaged MYLAR tape. * Use caution not to wrap the drain wire in the tape (1). * Follow the splicing instructions for copper wire and splice the drain wire. * Wrap the drain wire around the conductors and tape with electrical tape to replace the outer insulation. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Wiring Repairs Wiring Repairs The Wiring Repairs section contains the following types of wiring repair information. Using these elements together will make wiring repair faster and easier: * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Flat Wire Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Flat Wire Repairs) * GMLAN Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/GMLAN Wiring Repairs) * High Temperature Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/High Temperature Wiring Repairs) * Heated Oxygen Sensor Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Heated Oxygen Sensor Wiring Repairs) * Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves) * Splicing Twisted or Shielded Cable (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Twisted or Shielded Cable) * Splicing Inline Harness Diodes (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Inline Harness Diodes) * SIR/SRS Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/SIR/SRS Wiring Repairs) US English/Metric Conversion US English/Metric Conversion Page 7059 4. Grasping the tire at the 3 o'clock (2) and 9 o'clock (1) positions, gently push in on one side of the tire to remove any lash. 5. Zero the J-8001 - Dial Indicator. 6. On the same side of the tire previously pushed inwards, gently pull outwards and measure the lash. 7. Record the measurement seen on the J-8001 - Dial Indicator. 8. If the measured value exceeds 0.5 mm (0.02 in) then replace the outer tie rod. Refer to Steering Linkage Outer Tie Rod Replacement (See: Service and Repair/Steering Linkage Outer Tie Rod Replacement). 9. Repeat the procedure for the other side. Page 7965 6. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals on to the bare wire using the J38125-7 crimp tool, jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 7. Position the wire seal to the terminal and crimp the seal and insulation using the J-38125-6 crimp tool, jaw 1 (1). The completed terminal and seal should appear as shown above (body harness connector shown). Note Avoid getting solder on the terminal end or overheating the terminal. Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. 8. Solder all four terminals at the wire crimp. 9. Slide the two body harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Page 5150 Page 3934 6. Install the cooler line into the quick connect fitting. 7. Insert the cooler line end into the quick connect fitting until a click is either heard or felt. 8. Do not use the plastic cap on the cooler line in order to install the cooler line into the fitting. 9. Pull back sharply on the cooler line in order to ensure that the cooler line is fastened into the quick connect fitting. Important: Do not manually depress the retaining clip when installing the plastic cap. 10. Position (snap) the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the plastic cap onto the quick connect fitting. 11. Ensure that the plastic cap is fully seated against the fitting. 12. Ensure that no gap is present between the cap and the fitting. Page 9509 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Page 5850 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. Page 8200 Page 5933 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Page 5501 Heated Seat Switch - Passenger (KA1) Page 1380 FUSE PULLER .................................................................................................................................... ............................................................ Fuse Puller Locations Transmission Speed Sensor: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH2) Locations Power Distribution Module: Locations Luggage Compartment/Rear of Vehicle Component Views Rear Window Shelf Components 1 - Cellular (UE1) and Digital Radio Antenna (U2K) 2 - Radio Antenna Module 3 - Remote Start Antenna (AP3) 4 - Speaker - Right Rear 5 - Accessory AC/DC Power Control Module (KV1) 6 Audio Amplifier (UQ3) 7 - Rear Compartment Courtesy Lamp 8 - Remote Control Door Lock Receiver (RCDLR) 9 - Digital Radio Receiver (U2K) 10 - Speaker - Left Rear Page 9154 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 8252 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 2128 Heater Core: Service and Repair Heater Core Replacement Heater Core Replacement Removal Procedure 1. Remove the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation (See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair). 2. Remove the center floor air outlet duct screws. 3. Remove the center floor air outlet duct. 4. Drill out the heater core cover heat stakes. 5. Remove the heater core cover screws. 6. Remove the heater core cover. Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement Special Tools J 43631 Ball Joint Remover Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove and support the brake caliper and bracket as an assembly, and remove the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement ). 4. Rotate the bearing hub to a position where the least amount of interference between the stud and the steering knuckle exists. 5. Using the J 43631, release the wheel stud from the bearing hub and discard the stud. Installation Procedure Diagram Information and Instructions Seat Heater: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Page 4645 Automatic Transmission Output Shaft Speed (OSS) Sensor (ME7 or MN5) Page 1258 Hose/Line HVAC: Service and Repair Suction Hose Replacement Suction Hose Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery and Recharging). 2. Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs. 3. Remove the compressor hose and liquid line connector. 4. Remove the suction hose from the compressor hose. 5. Remove and discard the O-rings. 6. Remove the surge tank from the surge tank bracket. 7. Remove the suction hose and liquid line nut from the thermal expansion valve (TXV). 8. Remove the suction hose and liquid line from the TXV. Page 1662 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Page 5245 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Seat Belts Repairs and Inspections Required After a Collision: Service and Repair Seat Belts Repairs and Inspections Required After a Collision Warning Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: * Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. * Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. * Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. * Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Page 8283 SIR/SRS Wiring Repairs SIR/SRS Wiring Repairs Special Tools J-38125 Terminal Repair Kit The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as connectors and terminals. Note: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a terminated lead from the SIR Repair Kit Tray. The tool kit J-38125 contains the following items: * DuraSeal splice sleeves, in order to repair the SIR/SRS wiring * A special crimping tool * A heat torch * An instruction manual The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors SIR/SRS Connector Repair (Plastic Body and Terminal Metal Pin) The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. Do not substitute any other terminals for those in the repair kit. The J-38125 SIR/SRS Terminal Repair Kit contains: * Various terminated leads for sensing and diagnostic module (SDM) terminal replacement * Various connector positive assurance (CPA) locks for SIR/SRS connectors * Base of steering column pigtail connectors part number 12085514 Page 2220 7. Connect the lower right HO2S electrical connector to the engine wiring harness electrical connector (2). 8. Install the CPA retainer (3). 9. Install the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement (See: Steering and Suspension/Suspension/Stabilizer Bar/Service and Repair/Rear Suspension). 10. Install the muffler assembly. Refer to Exhaust Muffler Replacement (See: Muffler/Service and Repair). Page 3849 13 - Front Differential Transfer Driven Gear 14 - Front Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 - Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 - Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual Valve Disassembled Views Disassembled Views Case and Associated Parts Page 9915 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Page 4033 Control Module: Diagrams Component Connector End Views Automatic Transmission Auxiliary Fluid Pump Control Module (HP7 with ME7) Transmission Control Module (TCM) (ME7) Page 1405 Fuse Block - Underhood X1 Page 5516 Ignition Coil 4 (LAT or LE5 or LE9) Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 2. Remove the engine cover, if required. 3. Remove the fuel rail service port cap. 4. Wrap a shop towel around the fuel rail service port and using a small flat bladed tool, depress (open) the fuel rail test port valve. 5. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 6. Install the fuel rail service port cap. 7. Install the engine cover, if required. 8. Tighten the fuel fill cap. Locations Transmission Position Switch/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components (ME7 or MN5) 1 - Park/Neutral Position (PNP) Switch Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) Page 9174 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 1037 64 - Band Anchor Pin (Lo/Reverse) 65 - Oil Level Control Plug 81 - Tube Assembly Bolt/Bottom Pan Bolt 84 - Transaxle Oil Filter Seal 85 - Transaxle Oil Filter Assembly 86 - Oil Level Control Valve 87 - Transaxle Bottom Pan Gasket 88 - Transaxle Oil Pan 89 - Chip Collector Magnet 120 Chip Collector Magnet (Some Models) 126 - Side Cover Stud 130 - A/Trans Auxiliary Fluid Pump Assembly 131 - Auxiliary Trans Fluid Pump Bolts 132 - Auxiliary Pump Pipe Bolts Component Location Component Location Transmission Major Components 1 - TFP Manual Valve Position Switch Assembly 2 - Control Valve Body Assembly Page 7693 For vehicles repaired under warranty, use the table. Disclaimer Page 3488 Throttle Body: Removal and Replacement Throttle Body Assembly Replacement Removal Procedure Caution: Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces. Caution: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components. Note: DO NOT prop open the throttle blade with the ignition key in the ON position as it may set a diagnostic trouble code (DTC). 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (2) from the electronic throttle control (ETC) (1). Page 9412 1 - Seat Back Cover - Passenger 2 - Heated Seat Element - Passenger Back (KA1) 3 - Seat Back Cushion Pad - Passenger 4 - Seat Belt Switch - Passenger 5 - Seat Horizontal Motor - Passenger (1LZ) 6 - Seat Rear Vertical Motor - Passenger (1LZ) 7 - Heated Seat Control Module - Passenger (KA1) 8 - Seat Front Vertical Motor - Passenger (1LZ) 9 - Heated Seat Switch - Passenger (KA1) 10 - Seat Adjuster Switch - Passenger (1LZ) 11 - Inflatable Restraint Front Passenger Presence System (PPS) Module 12 - Seat Cushion - Passenger 13 - Heated Seat Element - Passenger Cushion (KA1) 14 - Seat Cover - Passenger Page 5499 Heated Seat Control Module - Passenger X3 (KA1) Engine Controls - MIL ON/DTC P0172 Set Engine Control Module: Customer Interest Engine Controls - MIL ON/DTC P0172 Set TECHNICAL Bulletin No.: 10-06-04-004A Date: January 13, 2011 Subject: Intermittent Illumination of Malfunction Indicator Lamp (MIL)/Check Engine Light, DTC P0172 Set (Verify Alcohol Content Information in PCM) Models: 2010 Chevrolet Malibu Equipped with 2.4L 4 Cylinder Engine (VINs B, 0 - RPOs LE5, LE9) Please refer to GWM/IVH Supercede: This bulletin is being revised to update the engine type codes. Please discard Corporate Bulletin Number 10-06-04-004 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an intermittent illumination of the malfunction indicator lamp (MIL)/check engine light. Technicians may find a DTC P0172 set. Correction Use the procedure below to determine if the PCM has the incorrect alcohol content information. 1. Verify the actual measured percentage of alcohol content using the J-44175-A tester. Refer to Alcohol in Fuel Diagnosis in SI. If the actual alcohol is less than 15%, determine the "Fuel Alcohol Content" using the Tech 2(R). 2. Install the Tech 2(R) and build the vehicle as a 2010 and select Powertrain. 3. Build the vehicle with an LE9 engine (even if it has the LE5 engine). - Select Special Functions. - Select Fuel System (F2). Page 1601 Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application The tire must be in the relaxed position when the repair unit is installed. Do not spread the beads excessively. Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. Page 388 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 5650 Automatic Transmission Manual Shift Switch - Right (KB7) Page 3535 Ignition Coil 4 (LAT or LE5 or LE9) Page 9119 Page 3050 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 4571 Transmission Mode Indicator - A/T: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Automatic Transmission Control Indicator Replacement Page 1257 17. Install the liquid line bracket bolt and tighten to 10 Nm (89 lb in). 18. Install the refrigerant pressure sensor and tighten to 5 Nm (44 lb in). 19. Install the refrigerant pressure sensor wire harness connector. 20. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery and Recharging). 21. Leak test the fittings using the J 39400-A. 22. Install the surge tank to the surge tank bracket. Page 5168 Page 1433 threads. 5. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 6. Install the electrical ground terminal to the new, conductive M7 bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Install the M7 bolt and tighten to 9 Nm (80 lb in). 8. Check for proper system operation. M6 Weld Nut (Alternative Repair) Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a conductive M6 bolt and a conductive M6 nut may be used to secure the electrical ground terminal. Refer to GM parts catalog for the correct part number and application. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 ) clearance behind the panel surface and 20 mm (0.79 ) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M6 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M6 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M6 nut and tighten to 8 Nm (71 lb in). Note: The repair area must be properly refinished to maintain positive electrical grounding. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair (). 11. Check for proper system operation. M8 Weld Nut Caution: Use GM approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a conductive M8 bolt and a conductive M8 nut may be used to secure the ground terminal. Refer to GM parts catalog for the correct part numbers and application. 2. Select a location adjacent to M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note: Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Carefully remove paint and primer from the area surrounding the new ground site until bare metal is visible. 6. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the new, conductive M8 bolt threads. 7. Carefully remove any corrosion from the electrical ground terminal. Refer to Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections). 8. Install the electrical ground terminal and new, conductive M8 bolt to the ground location. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 9. Install the conductive M8 nut and tighten to 22 Nm (16 lb ft). Note: The repair area must be properly refinished to maintain positive electrical grounding. Locations Refrigerant Pressure Sensor / Switch: Locations Front of Vehicle/Engine Compartment Component Views Front and Right Rear of the Engine Compartment Components 1 - A/C Refrigerant Pressure Sensor 2 - Engine Cooling Fan - Right 3 - Engine Cooling Fan - Left 4 - Windshield Washer Fluid Pump 5 - Windshield Washer Fluid Level Switch 6 - Horn Assembly Page 1570 Page 4031 Control Module: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 2564 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 8944 Rear Side Door Opening Floor Carpet Retainer Replacement Rear Side Door Opening Floor Carpet Retainer Replacement Service Precautions Power Steering Line/Hose: Service Precautions Power Steering Hose Disconnected Caution Caution: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system. Page 5432 Page 877 4. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 5. Install the shift control cable to transaxle range switch lever and verify proper operation. Page 6743 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 3407 3. This step applies to the Bartholomew style connectors ONLY. Squeeze the plastic quick connect fitting release tabs. 4. This step applies to the Q release type connectors ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting. 5. This step applies to the Squeeze to release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick connect fitting. Page 9445 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Page 6368 Knock Sensor (KS) 1 (LZ4 or LZE or LY7) Knock Sensor (KS) 2 (LZ4 or LZE or LY7) Locations Power Door Lock Switch: Locations Door Component Views Driver Door Components 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Passenger Door Components Page 5622 Window Switch - Driver X1 Window Switch - Driver X2 Page 5729 Power Distribution Module: Diagrams Component Connector End Views Accessory AC/DC Power Control Module X1 (KV1) Accessory AC/DC Power Control Module X2 (KV1) Page 1475 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 5984 Service and Repair Sunroof / Moonroof Frame: Service and Repair Sunroof Frame Replacement Removal Procedure Note: A new sunroof module assembly does not include the sunroof window, the motor, the sunshade, or the finishing lace as components. You must install the old components to the new sunroof module assembly. 1. Remove the sunroof window. Refer to Sunroof Window Replacement (See: Sunroof / Moonroof Panel/Service and Repair) 2. Remove the sunshade panel. Refer to Sunroof Sunshade Replacement (See: Sun Shade/Service and Repair/Sunroof Sunshade Replacement) 3. Remove the sunroof finishing lace. Refer to Sunroof Opening Trim Finish Lace Replacement (See: Sunroof / Moonroof Interior Trim Panel/Service and Repair) 4. It is only necessary to lower the headliner. Perform the headliner replacement removal step 1 thru 21. Refer to Headlining Trim Panel Replacement (See: Interior Moulding / Trim/Headliner/Service and Repair) 5. Disconnect the front sunroof drain hoses from the drain spigot. Page 2352 Page 778 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor - Bank 1 Exhaust (LY7) Camshaft Position (CMP) Sensor - Bank 1 Intake (LY7) Specifications Axle Nut: Specifications Front axle nut ....................................................................................................................................... .................................................... 215 Nm (159 lb ft) Page 4869 Installation Procedure 1. Inspect the reservoir for cracks or deformities. If found, replace the reservoir. 2. Clean the reservoir with clean denatured alcohol, or equivalent. 3. Dry the reservoir with non-lubricated, filtered air. 4. Lubricate the new seals and the reservoir bayonets with GM approved or equivalent brake fluid from a clean, sealed brake fluid container. 5. Install the seals, making sure they are fully seated. 6. Install the reservoir onto the master cylinder by pressing straight down by hand until pin holes are aligned. 7. Carefully tap in the reservoir retaining pins to secure the reservoir. 8. Fill the master cylinder reservoir. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 9. Install the brake fluid level sensor. Refer to Brake Fluid Level Indicator Switch Replacement (See: Brake Fluid Level Sensor/Switch/Service and Repair). 10. Remove the master cylinder from the vise. 11. Install the master cylinder to the vehicle. Refer to Master Cylinder Replacement (See: Brake Master Cylinder/Service and Repair/Removal and Replacement). Page 8100 1 - Inflatable Restraint Front End Sensor - Left 2 - Ambient Air Temperature Sensor 3 - Inflatable Restraint Front End Sensor - Right Door Component Views Driver Door Components Front Suspension Wheel Bearing: Service and Repair Front Suspension Front Wheel Bearing and Hub Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 3. Disconnect the wheel speed sensor electrical connector, if equipped. 4. Remove the wheel speed sensor electrical connector from the mounting bracket, if needed. 5. Loosen the wheel drive shaft from the wheel bearing/hub. Refer to Wheel Drive Shaft Replacement (See: Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement). Page 4170 Page 6284 Page 4036 Transmission Control Module (TCM) (MN5 with LZ4 or LZE) Page 5670 Page 6072 8. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 9. Insert the wire into the DuraSeal splice sleeve barrel until the wire hits the barrel stop. 10. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 11. Using the heat torch, apply heat to the crimped area of the barrel. 12. Gradually move the heat barrel to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 7387 Disclaimer Page 7166 7. Wipe off any excessive grease on the intermediate shaft to avoid damage from drips on the carpet. 8. Install the instrument panel insulator panel - left side. 9. Verify that the noise is no longer present. Condition 2 There may be interference between the clamp and the steering gear input shaft. The clamp is beveled and if forced down on the input shaft too hard, it may cause a loose fit with the intermediate shaft to input shaft joint. Correction 2 To correct this condition, perform the following steps: 1. Remove the intermediate shaft pinch bolt at the steering gear end. 2. Install a new bolt, GM P/N 07845238, but do not tighten the bolt at this time. 3. Pry the clamp up using a pry bar to position the bolt into the upper part of the groove as shown above. This will position the clamp off the bevel. 4. While keeping the clamp in the upper position, tighten the bolt. Tighten Tighten the bolt to 49 Nm (36 lb ft). 5. Verify that the clunk noise is no longer present. Condition 3 Important This condition ONLY applies to 2004-2007 Chevrolet Malibu/Maxx and 2005-2007 Pontiac G6. Some customers may comment on a knocking or rattling type noise from the front of the vehicle when driven at low speeds and over bumps. The noise only occurs when the steering wheel is in the straight ahead position and sounds like the noise is in the left suspension of the vehicle or directly in front of the driver. Correction 3 1. Ensure the noise is not caused by Condition # 1. 2. Determine the source of the noise. Install the chassis ears at the following locations: - sway bar link - one side at a time - upper strut mount - one side at a time - steering gear near the pinion area - base of the steering column housing - radiator surge tank 3. If the noise is coming from the upper strut mount or sway bar link, replace as necessary and retest. 4. For 2004-2006 Chevrolet and Pontiac model year vehicles, the noise may be coming from the radiator surge tank area. (The 2007 model year vehicles use a different style radiator surge tank - refer to Step 9.) 5. If the noise is coming from the radiator surge tank, release the two retaining tabs holding the radiator surge tank and reposition the tank away from the attaching bracket and isolate with closed cell foam. 6. Cut three pieces of closed cell foam, P/N P46515 (or equivalent), into 25 mm (1 in) by 102 mm (4 in) pieces. 7. Cut two pieces of closed cell foam into 25 mm (1 in) by 6 mm (1/4 in) pieces. Page 9332 Sunroof / Moonroof Motor: Service and Repair Sunroof Motor/Actuator Replacement Removal Procedure Note: The sunroof actuator drive shaft turns in both directions and contains no limit switches. You may replace the sunroof motor/actuator with the window panel in any position. 1. It is only necessary to lower the headliner. Only do those step in headliner replacement that will lower the headliner enough to gain access to the part. Refer to Headlining Trim Panel Replacement (See: Interior Moulding / Trim/Headliner/Service and Repair). 2. Disconnect the electrical connector from the motor/actuator. 3. Remove the screws from the sunroof motor. 4. Pull straight down to disengage the drive gear from the cables housed within the sunroof cable drive tubes. 5. Remove the sunroof motor from the sunroof module. Page 5427 Door Lock Switch - Passenger Page 5711 Air Inlet Grille Panel Replacement Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Air Inlet Grille Panel Replacement Locations Crankshaft Position Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Adjustments Rear Door Striker: Adjustments Door Lock Striker Adjustment Note: To determine if the striker adjustment is required, proceed as follows. 1. Ensure that the door is properly aligned with the door opening before proceeding with the striker adjustment. 2. Open and close the door on the striker (2). Note if the door drags on the striker causing the door to move upward or downward upon contact with the striker. Also note the closing effort to fully engage the latch. Note: When the striker bolts have been removed, the striker anchor plate (1) will slip down in the door pillar or quarter panel and the trim will need to be removed to gain access. 3. Using a soft marker, mark around the striker (2) for reference of the original position. Loosen the striker screws just enough to allow the movement of the door striker and shims if equipped. 4. Adjust the door striker up or down and inboard or outboard as required. Page 1416 Fuse Block - Rear Bottom View Service and Repair Keyless Entry Module: Service and Repair Remote Control Door Lock Receiver Replacement Page 3307 7. Remove the brake, fuel, and EVAP pipe clips (1, 2) from the studs on the front of dash. 8. Remove the brake pipes from the clips. 9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 10. Remove the right rear frame bolts (4). 11. Remove the right rear frame reinforcement (3). Page 2876 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 1944 1. Install a NEW intake manifold gasket if necessary, otherwise install the old gasket. 2. Install the intake manifold. 3. Install the intake manifold upper bolt and nuts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the intake manifold lower bolts (1). Tighten the bolts/nuts (1) to 10 Nm (89 lb in). Page 2154 Removal Procedure 1. Remove the front fasica. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 2. Remove the upper radiator air deflector. Installation Procedure Important: Radiator air deflector must be properly installed or reduced A/C and engine cooling system performance could occur. 1. Install the upper radiator air deflector. 2. Install the front fasica. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). Page 1326 Engine Oil: Fluid Type Specifications ENGINE OIL TYPE Look for three things: 1. Your vehicle's engine requires oil meeting GM Standard GM6094M. 2. Oils meeting these requirements should also have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). You should look for this information on the oil container 3. All temperatures above -20°F (-29°C) SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 10W-40, SAE 20W-50, or any other viscosity grade not recommended. NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. ENGINE OIL ADDITIVES / ENGINE OIL FLUSHES Do not add anything to your oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all you will need for good performance and engine protection. Engine oil system flushes are not recommended and could cause engine damage not covered by the vehicle warranty. Page 3777 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement Heater Inlet Hose Replacement Special Tools J 38185 Hose Clamp Pliers Warning With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. Removal Procedure 1. Partially drain the coolant. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 2. Remove the surge tank from the surge tank bracket. 3. Reposition the heater inlet hose clamp at the heater core using the J 38185. 4. Remove the heater inlet hose from the heater core. Page 8942 Carpet: Removal and Replacement Front Floor Panel Carpet Replacement Front Floor Panel Carpet Replacement Front Side Door Opening Floor Carpet Retainer Replacement Front Side Door Opening Floor Carpet Retainer Replacement Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Page 3397 Fuel Injector Replacement (See: Service and Repair) Page 2948 Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (LAT or LE5 or LE9) Manifold Absolute Pressure (MAP) Sensor (LY7) Page 4772 WARRANTY INFORMATION A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Page 4908 8. Connect the vacuum brake booster check valve (1) to the vacuum brake booster grommet (4). 9. Position the radiator surge tank to the bracket. Refer to Radiator Surge Tank Replacement (See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Radiator Surge Tank Replacement). 10. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding). Page 3722 1 - Control Valve Body Cover Bolt 2 - Control Valve Body Cover Assembly 3 - Control Valve Body Cover Gasket 4 - Control Valve Body Bolt 5 - Control Valve Body Cover Hole Seal 6 - Control Solenoid Valve Heat Sink Bolt 7 - Control Solenoid (w/Body and TCM) Valve Assembly 8 - Control Valve Body Filter Plate Assembly 9 - Control Valve Body Bolt 10 - Control Valve Body Bolt 11 Control Valve Body Assembly 12 - Control Valve Body Spacer Plate Assembly 13 - A/Trans Fluid Level Control Valve 14 - A/Trans Fluid Level Control Valve Gasket 15 - A/Trans Output Speed Sensor Bolt 16 - A/Trans Output Speed Sensor Assembly 17 - Manual Shaft Detent Spring Bolt 18 - Manual Shaft Detent Lever Spring Assembly 19 - A/Trans Input Speed Sensor Assembly 20 A/Trans Input Speed Sensor Assembly O-Ring Seal 21 - A/Trans Input Speed Sensor Bolt 22 - Fill Cap 23 - Fill Cap Seal 24 - Torque Converter Housing Gasket Page 8217 Keyless Entry Transmitter: Diagnostic Aids Arrows and Symbols Arrows and Symbols This service manual uses various symbols in order to describe different service operations. 1 - Front of Vehicle 2 - View Detail 2 - View Detail 3 - Ambient Air Mixed with Another Gas or Indicate Temperature Change 4 - Motion or Direction 5 - View Angle 6 - Dimension (1:2) 7 Ambient/Clean Air Flow or Cool Air Flow 8 - Lubrication Point - Oil or Fluid 9 - Task Related 10 Sectioning (1:3) 11 - Gas Other Than Ambient Air or Hot Air Flow 12 - Lubrication Point - Grease or Jelly 13 - Multidirectional Arrow Decimal and Metric Equivalents Decimal and Metric Equivalents Page 2177 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 6571 Fuse Block - Underhood Top View (LY7) Heated Oxygen and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Page 579 Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Page 2815 Page 4179 Shifter A/T: Service and Repair 6T70/6T75 - Automatic Transmission Transmission Control Lever Knob Replacement Transmission Control Lever Knob Replacement Removal Procedure 1. Release the boot (2) from the shift control knob (1) by pulling the boot retainer downward. 2. Remove the shift knob retaining screw (3). 3. Remove the shift knob (1) from the shift control. Installation Procedure Page 4649 1. Install the 3 input speed sensor seals (1). 2. Install the input speed sensor (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the input speed sensor bolt (2) M6 x 23 and tighten to 12 Nm (106 lb in). 4. Connect the input speed sensor electrical connector (1). 5. Install the transmission control valve body cover. Perform the service fast learn adapt procedure. Refer to Service Fast Learn Adapts (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning/6T30/6T40/6T45 - Automatic Transmission). Page 4097 64 - Band Anchor Pin (Lo/Reverse) 65 - Oil Level Control Plug 81 - Tube Assembly Bolt/Bottom Pan Bolt 84 - Transaxle Oil Filter Seal 85 - Transaxle Oil Filter Assembly 86 - Oil Level Control Valve 87 - Transaxle Bottom Pan Gasket 88 - Transaxle Oil Pan 89 - Chip Collector Magnet 120 Chip Collector Magnet (Some Models) 126 - Side Cover Stud 130 - A/Trans Auxiliary Fluid Pump Assembly 131 - Auxiliary Trans Fluid Pump Bolts 132 - Auxiliary Pump Pipe Bolts Component Location Component Location Transmission Major Components 1 - TFP Manual Valve Position Switch Assembly 2 - Control Valve Body Assembly Page 1087 Wiper Switch: Service and Repair Windshield Wiper and Washer Switch Replacement Page 9278 Note: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. 1. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel. 2. Prepare all mating surfaces as necessary. 3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces. Refer to Anti-Corrosion Treatment and Repair (). 4. Position the tie bar to the vehicle using 3-dimensional measuring equipment. Clamp the tie bar into place. 5. Plug weld accordingly. 6. Clean and prepare all welded surfaces. 7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (). 8. Paint the repair area. Refer to Basecoat/Clearcoat Paint Systems (See: Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems). 9. Install all related panels and components. 10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 11. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Page 6478 Automatic Transmission Manual Shift Switch - Left (KB7) Page 8219 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Page 5487 Component Connector End Views Hazard Warning Switch Headlamp - Left High Beam A/T Controls - Downshift Hesitation/Delayed Shifting Control Module: All Technical Service Bulletins A/T Controls - Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 4509 Automatic Transmission Output Shaft Speed (OSS) Sensor (ME7 or MN5) Page 3296 Canister Vent Valve: Diagrams Component Connector End Views Evaporative Emission (EVAP) Canister Vent Solenoid Valve Page 6656 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 9001 Glove Compartment: Service and Repair Instrument Panel Lower Compartment Replacement Instrument Panel Lower Compartment Replacement Page 2555 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor. 3. Remove the CKP sensor bolt. 4. Remove the CKP sensor. Installation Procedure Page 1389 Page 9688 Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 6088 Auxiliary Power Outlet: Description and Operation Power Outlets Description and Operation 12 Volt Power Outlet Receptacle Description and Operation The 12 V accessory power receptacles are supplied B+ all the time. 110 Volt Power Outlet Receptacle System Description The alternating current (AC) accessory power outlet system consists of the accessory DC/AC power inverter module and the accessory power receptacle - 110 V AC. The accessory DC/AC power inverter module converts 12 V direct current (DC) battery power to 110 V at 60 Hertz (Hz) AC power to operate AC powered devices. The accessory DC/AC power inverter module provides up to 150 watts of power. The accessory power receptacle - 110 V AC provides the usual connection for AC powered devices. 110 Volt Power Outlet Receptacle System Operation The accessory DC/AC power inverter module receives fuse protected battery voltage and is connected to the 12 V electrical system ground. The accessory power receptacle - 110 V AC has an internal switch, that detects when an AC powered device is plugged into the outlet. When the ignition is ON, and an AC powered device is plugged into the accessory power receptacle - 110 V AC, the normally open switch in the accessory power receptacle - 110 V AC, closes. When the accessory DC/AC power inverter module detects the voltage from the accessory power receptacle - 110 V AC switch, the inverter module begins to supply 110 V AC to the accessory power receptacle - 110 V AC after a 1.5 second delay. The accessory AC power system is protected against circuit overload and circuit shorts to ground. 110 Volt Power Outlet Receptacle Isolation Fault Protection The accessory DC/AC power inverter module contains a ground fault circuit interrupter (GFCI). GFCI monitors the 110 V circuit for a short to vehicle chassis ground. If a 110 V AC short to ground is detected, the accessory DC/AC power inverter module will turn OFF. The module remains OFF, until the AC powered device is unplugged from the outlet, and then plugged into the outlet after a 3 second delay. 110 Volt Power Outlet Receptacle Overload Shutdown The accessory DC/AC power inverter module will turn OFF if the current in the 110 V circuit is greater than 3.8 A for 1 second, or 2.5 A for 10 seconds. The module will turn ON again, when the AC powered device is unplugged from the outlet, and then plugged into the outlet after a 3 second delay. 110 Volt Power Outlet Receptacle Internal Shutdown The accessory DC/AC power inverter module will turn OFF if the B+ supply voltage is greater than 16.5 V or less than 11 V. The module will also turn OFF if the device temperature is greater than 85°C (185°F). The module will turn ON again, after the shutdown condition is corrected, and the AC powered device is unplugged from the outlet, and then plugged into the outlet. Page 1946 10. Install the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Rail/Service and Repair). 11. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement (See: Engine Lubrication/Engine Oil Dip Stick - Dip Stick Tube/Service and Repair). 12. Connect the EVAP canister purge tube to the intake manifold and the EVAP solenoid. Refer to Plastic Collar Quick Connect Fitting Service ( See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service ). 13. Connect the engine wiring harness electrical connector to the MAP sensor. 14. Install the throttle body. Refer to Throttle Body Assembly Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Removal and Replacement). 15. Install the vacuum brake booster hose (2) to the intake manifold. 16. Position the vacuum brake booster hose clamp (1) at the intake manifold. Page 3709 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). 6. Remove the alignment tool. Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 7. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Page 9220 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Passenger Front Door Lock Switch Replacement - Passenger Front Page 5209 1. Locate the lever lock on the wire dress cover. Remove the connector position assurance (CPA) and slide the lever lock away from the connector body. 2. Disconnect the connector from the component. 3. Locate the dress cover locking tabs on the dress cover of the connector. Using a small flat-blade tool release all of the locking tabs. Page 3158 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 6502 X101 Inline Harness Connector End Views X101 Left Front Wheel Speed Sensor Harness to Body Harness X102 Inline Harness Connector End Views Page 4150 Automatic Transmission/Control Valve Body Cover Replacement). 13. If a NEW TCM has been installed into the vehicle, the NEW module needs to be reprogrammed. Refer to Service Programming System (SPS) ( See: Testing and Inspection/Programming and Relearning/Service Programming System (SPS)). Note: The Service Fast Learn Adapts procedure must be performed when one of the following repairs have been made to the vehicle. Failure to perform the procedure after one of the following repairs may result in poor transmission performance, as well as transmission DTCs being set: * Transmission internal service/overhaul * Valve body repair or replacement * Control solenoid valve assembly replacement * TCM software/calibration update * Any service in response to a shift quality concern 14. Perform the Service Fast Learn Adapts. Refer to Service Fast Learn Adapts (See: Testing and Inspection/Programming and Relearning/6T70/6T75 - Automatic Transmission). Page 9105 Page 7635 Expansion Block/Orifice Tube: Service and Repair Air Conditioning Evaporator Thermal Expansion Valve Hose Replacement Air Conditioning Evaporator Thermal Expansion Valve Hose Replacement Page 9680 5. Remove the dress cover by using a flat bladed tool to release the dress cover locking tabs and lift up on the dress cover. 6. Cut the tie wrap that holds the wires to the connector body. 7. Use a small flat-blade tool to pry one side of the nose piece up to the pre-stage position. When the nose piece is in the pre-staged position, the nose piece will be raised above the connector body the length of the step in the nose piece. Page 119 Heated Seat Control Module - Passenger X3 (KA1) Page 1863 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. If equipped, install the tension stop (2) and fastener (1), then tighten to 10 Nm (89 lb in). 9. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). Page 9876 Page 4531 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid Page 6342 Ignition Coil 2 (LY7) Page 10333 Fog/Driving Lamp Switch: Service and Repair Fog Lamp Switch Replacement Page 676 Dimmer Switch: Service and Repair Instrument Panel Lamp Dimmer Switch Replacement Page 7370 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 3424 Page 9493 Page 1721 Disclaimer Page 10071 3. Locate the dress cover locking tabs at the corners of the connector. Use a small flat-bladed tool to release the locking tabs and remove the dress cover. 4. The terminal positive assurance (TPA) is located in the front of the connector. Page 6136 Fuse: Locations Instrument Panel Fuse Block - Owners Manual INSTRUMENT PANEL FUSE BLOCK The instrument panel fuse block is located on the instrument panel near the floor on the passenger side of the vehicle. Remove the panel cover to access the fuse block, then remove the fuse block cover to access the fuses. The vehicle might not have all the fuses and features listed. Page 8151 Hood Sensor/Switch (For Alarm): Diagrams Component Connector End Views Hood Ajar Switch (AP3 or HP7) Timing Chain Tensioner Replacement Timing Chain Tensioner: Service and Repair Timing Chain Tensioner Replacement Timing Chain Tensioner Replacement Special Tools J 45027 Tensioner Tool Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Remove the camshaft cover. Refer to Camshaft Cover Replacement (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 3. Remove the timing chain tensioner. 4. Remove the seal from the tensioner. Installation Procedure 1. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner or O-ring seal as applicable. 2. Measure the timing chain tensioner assembly from end to end. If the timing chain tensioner is to be replaced, a new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end. Page 5451 Page 3889 Control Module: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 6405 Secondary Air Injection (AIR) Pump Relay (NU6) Secondary Air Injection (AIR) Pump Solenoid (LE5 with NU6, or LE9 with NU5) Page 10194 Engine Oil Pressure (EOP) Switch (LY7) Page 934 1 - Inflatable Restraint Front End Sensor - Left 2 - Ambient Air Temperature Sensor 3 - Inflatable Restraint Front End Sensor - Right Door Component Views Driver Door Components Page 7697 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the HVAC module assembly to dash panel bolts (1) and tighten to 10 Nm (88 lb in). 3. Install the HVAC module assembly mounting bolts to the instrument panel reinforcement and tighten the bolts to 5 Nm (44 lb in). 4. Install the left hand side window defogger outlet duct. Page 7220 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 938 Inflatable Restraint Side Impact Sensor (SIS) - Right Page 5765 Page 7665 9. Remove the suction hose from the dash clip. 10. Remove the liquid line from the dash clip. 11. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 12. Remove the right front fender liner. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 13. Remove the right radiator air deflector retainers. 14. Remove the right radiator air deflector. 15. Remove the liquid line and compressor hose bolt from the condenser. Page 1196 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Inlet Duct Replacement Air Cleaner Inlet Duct Replacement Page 4739 Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 1. Remove the brake caliper from the brake caliper mounting bracket and support the brake caliper with heavy mechanic's wire (1), or equivalent. Do NOT disconnect the hydraulic brake flexible hose from the caliper. Refer to Front Brake Caliper Replacement (See: Front Brake Caliper Replacement). 2. Remove the brake pads (2) from the brake caliper bracket. 3. Remove the brake pad retainers (2) from the brake caliper bracket. 4. If reusing the bracket, thoroughly clean the pad hardware mating surfaces (1) of the caliper bracket, of any debris and corrosion. 5. Inspect the disc brake pad retainers (2) for the following: * Bent mounting tabs * Excessive corrosion * Looseness at the brake caliper mounting bracket * Looseness at the disc brake pads Page 6869 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 10125 3. If J 42059 tool fails to release the lighter socket from the retainer, perform the following alternate method: 1. Insert a small grinding tool with a cutoff wheel into the socket. 2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3. Use the J 42059 as directed above to remove the socket. Installation Procedure 1. Route the connector through the retainer. Align the accessory power receptacle retainer to the slot in the opening. 2. Install the retainer by pressing into place fully seated. 3. Connect the electrical connector to the receptacle. 4. Align the tabs on the receptacle to the slots in the retainer. Install the accessory power receptacle by pressing into place until fully seated. 5. Install the accessory power receptacle fuse. Page 6063 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Locations Throttle Position Sensor: Locations Instrument Panel/Center Console Component Views Lower Left Side of the Instrument Panel Components (1 of 2) 1 - Brake Pedal Position (BPP) Sensor 2 - Accelerator Pedal Position (APP) Sensor 3 - Accelerator Pedal 4 - Brake Pedal Page 871 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Page 1840 14. Use the EN-36017 - seal remover (1) to remove the valve seal. Installation Procedure 1. Using the EN-36017 - seal remover (1) install the NEW valve seal. Fully seat the seal onto the valve guide. Page 10730 17. Clean any excess auto-adhesive from the body. 18. Install the air inlet grille. Refer to Air Inlet Grille Panel Replacement (See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Air Inlet Grille Panel Replacement). 19. Install the windshield wipers arms and blades. Refer to Windshield Wiper Arm Replacement (See: Wiper and Washer Systems/Wiper Arm/Service and Repair). 20. Install the windshield side garnish moldings. Refer to Windshield Pillar Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Windshield Pillar Garnish Molding Replacement). 21. Install front edge of the headliner. 22. Install the sunshades. Refer to Sunshade Replacement (See: Body and Frame/Interior Moulding / Trim/Sun Visor/Service and Repair/Sunshade Replacement). 23. Install the inside rearview mirror. Refer to Inside Rearview Mirror Replacement (See: Body and Frame/Mirrors/Service and Repair/Inside Rearview Mirror Replacement). 24. Install the remote control door lock receiver. Refer to Remote Control Door Lock Receiver Replacement (See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Keyless Entry/Keyless Entry Module/Service and Repair). 25. Ensure that all electrical components operate properly. 26. Close the hood. Page 9799 Page 5072 12. Disconnect the engine wiring harness electrical connectors (2) from the ECM. 13. Remove the engine wiring harness clips (3) from the ECM/transmission control module (TCM) bracket (4). 14. Disconnect the engine wiring harness electrical connector (1) from the TCM. 15. Remove the ECM/TCM bracket bolt (1). 16. Slide the ECM/TCM bracket up and remove the bracket (2) (With the ECM and TCM still attached) from the battery tray. Page 7802 Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Owner Letter Owner Letter March 2011 Service and Repair Fuel Filler Neck: Service and Repair Fuel Tank Filler Pipe Housing Replacement Page 7043 9. Squeeze the 4 lock tabs on the intermediate steering shaft seal and pull the seal towards the inside of the vehicle in order to unseat the seal from the instrument panel compartment pass-through. 10. Remove the intermediate steering shaft from inside the vehicle. Installation Procedure 1. Position the intermediate steering shaft under the instrument panel. Note: Do NOT twist or squeeze the seal during installation. 2. Push the intermediate steering shaft seal forward from the inside of the vehicle until all four lock tabs are fully seated. 3. Ensure the seal is properly seated. In the engine compartment, inspect the 4 lock tabs for any damage. If the intermediate steering shaft seal lock tabs are damaged, replace the seal. 4. Connect the intermediate steering shaft to the steering column. Page 5294 connector housing. Refer to Repairing Connector Terminals in SI. 15. Insert the wire into the new conduit and tape the conduit end at the connector. Tape the conduit closed every 255 mm (10 in) with electrical tape. 16. Connect the fan end electrical connector into the cooling fan. 17. Fasten the new wire and conduit with tie wraps (GM P/N 12337820), as shown below. At the cooling fan end of the wire and conduit, leave adequate slack to allow for engine movement (white tie wraps are used for display purposes, use black tie wraps to match the original appearance). With RPO LY7 - Fasten the new wire and conduit to the existing harness with wire tie wraps as shown. With RPOs LZ9, LZ4 or LZE - Fasten the new wire and conduit to metal the transmission cooler lines as shown. (The lower cover has been removed to show the location of the wire tie wraps.) 18. Trim the wire and conduit to length at the underhood fuse block area. 19. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 20. Strip the wire insulation as required and install the terminal, GM P/N 15324340, on the wire. Refer to Repairing Connector Terminals in SI. 21. Reinstall the terminal into A2 on the junction block. Reinstall the TPA and the harness back cover. 22. Reconnect the harness to the under hood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 23. Reinstall the underhood fuse block into it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. Install the 40-amp fuse, GM P/N 15319478. 24. Reinstall the battery. Refer to Battery Replacement in SI. 25. Reinstall the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 26. Reinstall the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 27. Confirm the high speed cooling fan operation using the Tech 2(R). Parts Information Page 7058 Tie Rod: Testing and Inspection Steering Linkage Outer Tie Rod Inspection Steering Linkage Outer Tie Rod Inspection Special Tools J-8001 - Dial Indicator Set For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Note: This inspection procedure does not supersede local government required inspections that have more stringent requirements. 1. Inspect the outer tie rod end seal. If the outer tie rod end seal is torn, replace the outer tie rod end. Refer to Steering Linkage Outer Tie Rod Replacement (See: Service and Repair/Steering Linkage Outer Tie Rod Replacement). 2. Raise the side of the vehicle being inspected with a floor jack while maintaining contact between the opposite wheel and the shop floor. Support the lower control arm with a floor jack stand as far outboard as possible and remove the floor jack. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 3. Install the J-8001 - Dial Indicator between the outer tie rod end and the steering knuckle as shown in the graphic. Note that the tire and wheel assembly is shown removed only for clarification of the J-8001 - Dial Indicator position. Page 7950 Page 463 Page 7942 Note DO NOT replace the sensing and diagnostic module (SDM), side sensors or air bag modules. Note Both driver and passenger seats must be repaired when this concern occurs even if only one DTC code is set. The service kit contains sufficient components to repair both seat connectors. Connector Replacement Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above includes harness and connector clips, which are not required in this installation. Replace connectors on both driver and passenger seats, and then reposition the connectors following the steps below. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Note Only use hand tools to remove the seat to floor mounting bolts. If there are any problems with bolt removal, refer to Corporate Bulletin Number 10-08-50-002. 2. Remove the driver's seat to floor mounting bolts. Loosen the seat from the front retainers and tilt it back to expose the underside of the seat. Refer to Front Seat Replacement - Bucket in SI. Page 1571 Frequently Asked Questions Disclaimer Page 2180 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor (1) from the thermostat housing. Installation Procedure Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, Page 6864 1. Slide the steering wheel position sensor into place and remove the locating pin. 2. Connect any electrical connectors as needed. 3. Connect the intermediate steering shaft to the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering/Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 4. Remove anti-rotation pin J 42640. Page 5506 HVAC Control Module X1 (C60) HVAC Control Module X1 (C68) Page 1071 Power Window Switch: Service and Repair Front Side Door Window Switch Replacement - Left Side Front Side Door Window Switch Replacement - Left Side Page 9622 6T30/6T40/6T45 - Automatic Transmission Seals and Gaskets: Service and Repair 6T30/6T40/6T45 - Automatic Transmission Front Wheel Drive Shaft Seal Replacement - Left Side Front Wheel Drive Shaft Seal Replacement - Left Side Front Wheel Drive Shaft Seal Replacement - Right Side Front Wheel Drive Shaft Seal Replacement - Right Side Page 4923 3. Install the left rear park brake cable (2) to the crush bracket (5). 4. Install the right rear park brake cable (1) to the crush bracket (5). 5. Install the front floor console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 6. Install the 2 front cable plastic retainers to the body. 7. Install the front cable retainer screw and tighten to 2 Nm (18 lb in). Page 3937 Caution: Refer to Fastener Caution Note: The correct thread engagement is critical. Cross-threaded fittings can achieve proper tightness and still leak. 2. Install the oil cooler fitting to the radiator and tighten to 38 Nm (28 lb ft). 3. Install the transaxle oil cooler hoses to the oil cooler fittings on the radiator. Refer to Transmission Fluid Cooler Hose Replacement (See: Transmission Fluid Cooler Hose Replacement). 4. Fill the cooling system. 5. Adjust the transmission fluid level. 6. Inspect for fluid leaks. Page 7425 Air Door Actuator / Motor: Diagrams Component Connector End Views Air Temperature Actuator Mode Actuator Page 6505 X108 Engine Harness to the Body Harness (LZ4 or LZE) Page 10463 Combination Switch: Diagrams Component Connector End Views Turn Signal/Multifunction Switch X1 Turn Signal/Multifunction Switch X2 Locations Steering Control Module: Locations Instrument Panel/Center Console Component Views Instrument Panel Components - Steering Column 1 - Inflatable Restraint Steering Wheel Module Coil 2 - Power Steering Control Module (PSCM) Page 5477 Garage Door Opener (GDO) (UG1) Page 9920 2. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 3. Slide the lever lock forward while pressing down on the lever lock release tab. Page 7174 7. Wipe off any excessive grease on the intermediate shaft to avoid damage from drips on the carpet. 8. Install the instrument panel insulator panel - left side. 9. Verify that the noise is no longer present. Condition 2 There may be interference between the clamp and the steering gear input shaft. The clamp is beveled and if forced down on the input shaft too hard, it may cause a loose fit with the intermediate shaft to input shaft joint. Correction 2 To correct this condition, perform the following steps: 1. Remove the intermediate shaft pinch bolt at the steering gear end. 2. Install a new bolt, GM P/N 07845238, but do not tighten the bolt at this time. 3. Pry the clamp up using a pry bar to position the bolt into the upper part of the groove as shown above. This will position the clamp off the bevel. 4. While keeping the clamp in the upper position, tighten the bolt. Tighten Tighten the bolt to 49 Nm (36 lb ft). 5. Verify that the clunk noise is no longer present. Condition 3 Important This condition ONLY applies to 2004-2007 Chevrolet Malibu/Maxx and 2005-2007 Pontiac G6. Some customers may comment on a knocking or rattling type noise from the front of the vehicle when driven at low speeds and over bumps. The noise only occurs when the steering wheel is in the straight ahead position and sounds like the noise is in the left suspension of the vehicle or directly in front of the driver. Correction 3 1. Ensure the noise is not caused by Condition # 1. 2. Determine the source of the noise. Install the chassis ears at the following locations: - sway bar link - one side at a time - upper strut mount - one side at a time - steering gear near the pinion area - base of the steering column housing - radiator surge tank 3. If the noise is coming from the upper strut mount or sway bar link, replace as necessary and retest. 4. For 2004-2006 Chevrolet and Pontiac model year vehicles, the noise may be coming from the radiator surge tank area. (The 2007 model year vehicles use a different style radiator surge tank - refer to Step 9.) 5. If the noise is coming from the radiator surge tank, release the two retaining tabs holding the radiator surge tank and reposition the tank away from the attaching bracket and isolate with closed cell foam. 6. Cut three pieces of closed cell foam, P/N P46515 (or equivalent), into 25 mm (1 in) by 102 mm (4 in) pieces. 7. Cut two pieces of closed cell foam into 25 mm (1 in) by 6 mm (1/4 in) pieces. Page 4048 Page 6262 Electronic Brake Control Module (EBCM) (LY7 or LZ4 or LZE) Page 1687 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 5419 Digital Video Disc (DVD) Display - Driver Seat Headrest X2 (SPO Accessory) (UJ5) Page 5906 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Page 7041 Steering Shaft: Service and Repair Intermediate Steering Shaft Replacement Special Tools J-42640 - Steering Column Anti-rotation Pin Removal Procedure Note: The steering column tilt lever MUST be in the LOCK position in order ensure the tilt lever bracket remains rigid. 1. Ensure the steering column tilt lever is in the LOCK position. Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become UN-centered and cause possible damage to the SIR coil. If you think the SIR coil has became UN-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 2. With the front wheels in the straight ahead position, use the J-42640 - pin in order to lock the steering column. 3. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). Page 4104 25 - Torque Converter and Support and A/Trans Fluid Pump Housing Assembly 26 - Torque Converter and Differential Housing Bolt 27 - Torque Converter Assembly 28 - Dust Cover Push Pin - Model Dependent 29 - Dust Cover Bolt - Model Dependent 30 - Dust Cover - Model Dependent 31 - Front Differential Carrier Assembly 32 - Input Shaft Thrust Bearing Assembly 33 - A/Trans Case Cover Gasket 34 - A/Trans Case Cover Assembly 35 - A/Trans Case Cover Assembly Bolt A/Trans Case Cover, 2-6 and Low Reverse Pistons 400 - A/Trans Input Speed Sensor Assembly 401 - A/Trans Input Speed Sensor Bolt 402 - ISS O-Ring Seal 403 - A/Trans Case Cover Assembly 404 - 3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring 405 - 2-6 Clutch Piston 406 - 2-6 Clutch Spring Assembly 407 - 2-6 Clutch Spring Retainer Ring 408 - Low and Reverse Clutch Piston Assembly 409 - Low and Reverse Clutch Spring 410 Low and Reverse Clutch Spring Retainer Ring Locations Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) Locations Power Seat Motor: Locations Passenger Compartment/Roof Component Views Seat Components - Driver 1 - Seat Back Cover - Driver 2 - Heated Seat Element - Driver Back (KA1) 3 - Seat Back Cushion Pad - Driver 4 - Seat Recline Motor - Driver (1LZ) 5 - Seat Horizontal Motor - Driver (AG1 or 1LZ) 6 - Seat Rear Vertical Motor - Driver (AG1 or 1LZ) 7 - Heated Seat Control Module - Driver (KA1) 8 Seat Front Vertical Motor - Driver (AG1 or 1LZ) 9 - Seat Recline Switch - Driver (1LZ) 10 - Seat Adjuster Switch - Driver 11 - Seat Belt Switch - Driver 12 - Seat Cushion - Driver 13 - Heated Seat Element - Driver Cushion (KA1) 14 - Seat Cover - Driver Seat Components - Passenger Page 5760 Fuse Block - Rear X2 Page 3406 Fuel Line Coupler: Service and Repair Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service Removal Procedure Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Fuel/Service Precautions). Note: There are several types of plastic collar fuel and evaporative emission quick connect fittings that may be used on this vehicle. * Bartholomew (1) * Q release (2) * Squeeze to release (3) * Sliding retainer (4) * Push down TI (5) Note: The following instructions apply to all of these types of fittings except where indicated. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (See: Fuel Filter/Fuel Pressure Release/Service and Repair). Warning Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. 2. Using compressed air, blow any dirt out of the quick connect fitting. Page 1098 Frame Angle Measurement (Express / Savana Only) ........ Page 6453 Window Switch - Passenger Page 2466 Knock Sensor (KS) 2 (LZ4 or LZE or LY7) Page 9097 Page 9719 Ignition ON, operate the heated seat switch to the high and low heat positions. The seat cushion and seat back should get warm and the appropriate heated seat switch temperature indicators should illuminate. If the heated seat is inoperative, refer to the Heated Seat Circuit Test. If the heated seat switch indicator does not illuminate or is always illuminated, refer to the Heated Seat Switch Circuit Test. Circuit/System Testing Heated Seat Circuit Test 1. Ignition OFF, disconnect the harness connector at the appropriate heated seat switch. 2. Ignition ON, verify that a test lamp illuminates between the B+ circuit terminal 5 and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 3. Ignition OFF, connect the harness connector at the heated seat switch and disconnect the X1 harness connector at the appropriate heated seat module. 4. Test for less than 5 Ohms between the ground circuit terminal 1 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 5. Ignition ON, verify that a test lamp illuminates between the B+ circuit terminal 4 and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 6. Verify that a test lamp illuminates between the ignition circuit terminal 3 and ground. ‹› If the test lamp does not illuminate, test the ignition circuit for an open/high resistance. 7. Connect a test lamp between the signal circuit terminal 2 and ground. 8. Press and release the heated seat switch. The test lamp should turn ON and OFF when the switch is pressed and released. ‹› If the test lamp remains OFF, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, test or replace the heated seat switch. ‹› If the test lamp is always ON, test the signal circuit for an short to voltage. If the circuit tests normal, test or replace the heated seat switch. 9. Ignition OFF, disconnect the X3 harness connector at the heated seat module. 10. Test for infinite resistance between the signal, control, and low reference circuit terminals listed below and ground: * Seat cushion heater element voltage control terminal 1 * Seat cushion heater element ground control terminal 4 * Seat cushion temperature sensor signal terminal 3 * Seat cushion temperature sensor low reference terminal 2 ‹› If not the specified value, test the appropriate circuit for a short to ground. 11. Test for 2 k-15 kOhms between the signal circuit terminal 3 and the low reference circuit terminal 2. ‹› If not within the specified range, test or replace the seat cushion heater element. 12. Test for 0.5-5 Ohms between control circuit terminal 1 and control circuit terminal 4. ‹› If not within the specified range, test or replace the seat cushion heater element. 13. Disconnect the X2 harness connector at the heated seat module. 14. Test for infinite resistance between the control circuit terminals listed below and ground: * Seat back heater element ground control terminal 1 * Seat back heater element voltage control terminal 2 ‹› If not the specified value, test the appropriate circuit for a short to ground. 15. Test for 0.5-5 Ohms between control circuit terminal 1 and control circuit terminal 2. ‹› If not within the specified range, test or replace the seat back heater element. Page 1409 Fuse Block - Underhood X3 Page 755 Page 1097 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Page 4132 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Front of the Transmission Components (MH2 or MH8) Page 7921 Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information 1. Submit a transaction using the table below. * The amount identified in the Net Item column should represent the actual cost of the woven polyester electrical tape, required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a customer satisfaction program that affects your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle. Page 7567 HVAC Control Module X2 (C60) Service and Repair Steering Mounted Controls Assembly: Service and Repair Steering Wheel Control Switch Assembly Replacement Page 6573 Fuse Block - Underhood Bottom View Page 5785 Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Page 10178 ‹› If the MIL is illuminated, test the MIL control circuit terminal listed below for a short to ground. If the circuit tests normal, replace the IPC. * ECM terminal X1-27 for RPO LE5 * ECM terminal X1-12 for RPO LAT 3. Ignition ON, connect a 3A fused jumper wire between the MIL control circuit terminal listed below and ground. The MIL should illuminate. * ECM terminal X1-27 for RPO LE5 * ECM terminal X1-12 for RPO LAT ‹› If the MIL does not illuminate, test the MIL control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the IPC/bulb. 4. If all circuits/connections test normal, replace the ECM. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Instrument Cluster Replacement (See: Compass/Service and Repair) * Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement. setup, and programming Page 558 Seat Heater Switch: Service and Repair Driver or Passenger Seat Heater Switch Replacement Page 5863 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 43 Disclaimer Page 8049 Disclaimer Page 2001 26. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not aligned, repeat the portion of the procedure necessary to align the timing marks. 27. Install the fixed timing chain guide and bolts. Tighten the fixed timing chain guide bolts to 12 Nm (106 lb in). Page 870 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Automatic Transmission Electronic Components (MH8) Page 6050 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Locations Crankshaft Position Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 6371 Manifold Absolute Pressure (MAP) Sensor (LY7) Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: Customer Interest Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 2196 24. Connect the engine wiring harness electrical connector (1) to the ECT sensor. 25. Install the HO2S electrical connector rosebud clip to the thermostat housing. 26. Install the battery tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair). 27. Verify the drain valves at the radiator and water pump are closed. 28. Lower the vehicle. 29. Fill the cooling system. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). Page 8937 Disclaimer Page 4761 12. Fill the master cylinder auxiliary reservoir to the proper level. Refer to Master Cylinder Reservoir Filling (See: Hydraulic System/Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 13. Burnish the pads and rotors. Refer to Brake Pad and Rotor Burnishing (See: Procedures). Rear Disc Brake Pads Replacement Rear Disc Brake Pads Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 5. Remove the lower brake caliper guide pin bolt. Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 6. Pivot the brake caliper upward from the caliper bracket and support the caliper out of the way with heavy mechanic's wire or equivalent; ensure that there is no tension on the hydraulic brake flexible hose. Do NOT disconnect the hydraulic brake flexible hose from the caliper. Steering - Front End Clunk/Rattle/Knock On Bumps Steering Shaft: Customer Interest Steering - Front End Clunk/Rattle/Knock On Bumps TECHNICAL Bulletin No.: 06-02-32-007G Date: April 05, 2010 Subject: Clunk, Knock or Rattle Noise From Front of Vehicle While Driving or Turning Over Bumps at Low Speeds (Diagnose Noise and Perform Outlined Repair) Models: 2004-2006 Chevrolet Malibu Maxx 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn Aura Supercede: This bulletin is being revised to update the Parts Information for the bolt. Please discard Corporate Bulletin Number 06-02-32-007F (Section 02 - Steering). Condition 1 Some customers may comment on a clunk noise heard and felt in the steering wheel while driving at slow speeds and turning. The clunk noise may appear to be directly in front of the driver. Hitting a bump while turning can produce the clunk noise. Sometimes the noise may be duplicated when the vehicle is sitting still and the steering wheel is turned 90 degrees in either direction before initially centering the steering wheel. Cause 1 The clunk noise may be caused by a slip/stick condition between the inner and outer components of the intermediate shaft. Important Revised design intermediate shafts went into production in the 2009 model year and are the only design currently available through GMSPO since approximately September 2008. Since any model year vehicle could have had a second design shaft installed, it is critical to identify it before proceeding. The revised design intermediate shafts will NOT tolerate any type of lubricant per the following instructions. Adding lube to the second design shafts will cause a clunk noise in a very short period of time. Use the following pictures to identify which design of shaft you are servicing. Electric Assist Power Steering First Design - Bare Steel Tube (Lube OK) Page 9960 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 3626 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Front of the Transmission Components (MH2 or MH8) Page 2808 Page 1554 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Page 4338 21. Check for leaks. Control Valve Lower Body and Upper Body Replacement Control Valve Lower Body and Upper Body Replacement Removal Procedure 1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Control Valve Body Cover Replacement). 2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3). 5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring (8) to the side. Spring will be released with removal of lower control valve body. Audio - Buzz Noise When Using Bluetooth(R) Cellular Phone Microphone: All Technical Service Bulletins Audio - Buzz Noise When Using Bluetooth(R) TECHNICAL Bulletin No.: 10-08-44-003B Date: October 13, 2010 Subject: Buzz Noise During Call When Using Bluetooth(R) (Replace Microphone and Bezel) Models: 2009-2011 Buick Enclave, LaCrosse, Lucerne 2008-2011 Cadillac CTS, CTS-V 2009-2011 Cadillac DTS, Escalade, Escalade ESV, Escalade EXT, SRX, STS (with RPO YQ1 or YQ2), XLR 2009-2010 Chevrolet Cobalt, Corvette, Equinox, HHR, Impala, Malibu, Silverado, Suburban, Tahoe, TrailBlazer, Traverse 2010-2011 Chevrolet Camaro 2009-2010 GMC Envoy 2009-2011 GMC Acadia, Sierra, Yukon, Yukon XL 2009-2010 Pontiac G5, G6, Solstice, Torrent 2009-2010 HUMMER H2, H3 2009-2010 Saturn AURA, OUTLOOK, SKY, VUE 2009 Saab 9-7X All Equipped with OnStar(R) (UE1) and Bluetooth (UPF) Supercede: This bulletin is being revised to replace the microphone and bezel (if needed) and update model years. Please discard Corporate Bulletin Number 10-08-44-003A (Section 08 - Body and Accessories). Condition Some customers may comment on a buzz noise (from the land-line side only) during a call. On any vehicle equipped with OnStar(R) (UE1) and Bluetooth(R) (UPF), an electromagnetic compatibility (EMC) buzz can be heard from the land-line side only of the phone during a Bluetooth(R) phone call made with an older model global system for mobile communications (GSM) phone. The buzz is only heard with older model GSM phones and is dependent on the distance of the phone from the microphone. The newer 3G GSM phones or other cellular phones (CDMA, TDMA, etc.) have not shown this concern. Correction Equipped with Headliner Microphone (Cobalt, HHR (non-sunroof) H2, H3) A new microphone and bezel has been developed to address this concern. Replace the existing microphone with GM P/N 20951265. Also replace the bezel. Refer to the parts information table below for correct color/part number. Equipped with Overhead Console Microphone Page 1682 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Page 8729 Front Door Exterior Handle: Service and Repair Front Side Door Outside Handle Replacement Front Side Door Outside Handle Replacement Page 5988 Page 4392 8. Place approximately half of the grease from the service kit in the halfshaft inboard seal. Use the remainder of the grease to repack the housing. Note: Ensure the trilobal tripot bushing (3) is flush with the face of the housing (1). 9. Install the trilobal tripot bushing (3) to housing (1). 10. Position the larger new seal retaining clamp (2) on the halfshaft inboard seal. 11. Slide the housing (1) over the tripot joint spider assembly on the halfshaft bar. 12. Slide the large diameter of the halfshaft inboard seal (2), with larger clamp (3) in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove. 13. Position the joint assembly at the proper vehicle dimension, a = 106 mm (4.00 in). 14. Carefully insert a thin flat blunt tool, no sharp edges, between the large seal opening and the trilobal tripot bushing in order to equalize the pressure. Remove the tool. Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor Replacement - Intake Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (7) from the intake camshaft position (CMP) sensor (6). 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. Installation Procedure Page 8815 Rear Door Weatherstrip: Service and Repair Rear Door Upper Sealing Strip Replacement Rear Door Upper Sealing Strip Replacement Page 7272 Air Conditioning Compressor and Condenser Hose Replacement Hose/Line HVAC: Service and Repair Air Conditioning Compressor and Condenser Hose Replacement Air Conditioning Compressor and Condenser Hose Replacement Page 525 Pedal Positioning Sensor: Diagrams Component Connector End Views Brake Pedal Position (BPP) Sensor Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Relief Warning: Refer to Gasoline/Gasoline Vapors Warning (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel/Service Precautions). Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. 1. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure. 2. Remove the engine cover, if required. 3. Remove the fuel rail service port cap. 4. Wrap a shop towel around the fuel rail service port and using a small flat bladed tool, depress (open) the fuel rail test port valve. 5. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. 6. Install the fuel rail service port cap. 7. Install the engine cover, if required. 8. Tighten the fuel fill cap. Page 6356 Page 3187 Oxygen Sensor: Service and Repair Heated Oxygen Sensor Replacement - Sensor 2 Heated Oxygen Sensor Replacement - Sensor 2 Page 7820 Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Owner Letter Owner Letter March 2011 Page 2228 Tighten the bolts to 20 Nm (15 lb ft). 4. Install the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Left Side). 5. Lower the vehicle. 6. Install the exhaust manifold heat shield and bolts. Tighten the bolts to 10 Nm (89 lb in). Note: A special anti-seize compound is used on the HO2S threads. The compound consists of graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from an engine and is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation. 7. Coat the threads of the HO2S with anti-seize compound. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Fluid Type Page 3860 7. Remove the 2 control valve body bolts (4) M6 x 65. 8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95. 10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body and transmission control module (TCM) assembly (5). Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 12. Remove the control solenoid valve assembly filter plate (6). * Discard the filler plate. It is not reusable. * Inspect the pressure switch manifold seals for damage or contamination. Replace the control solenoid valve assembly as necessary. * Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage around the PCS seals. Replace the upper channel plate as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (1). Page 8204 6T30/6T40/6T45 - Automatic Transmission Parking Lock Cable: Adjustments 6T30/6T40/6T45 - Automatic Transmission Park Lock Cable Adjustment 1. Place the floor shift lever in the PARK position. 2. Turn the ignition key cylinder to the LOCK position. 3. If the front floor console is in place, remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). Important: * The key must not be able to be removed from the ignition cylinder with the transmission control lever in any position other than PARK. If they key can be removed in any other position, adjustment or repair is necessary. * The shift lever must not move from park unless the key is in the ON position. If the lever can be removed from park with the key in the OFF position, adjust or repair the park lock cable. 4. While using a small screwdriver to release the adjuster lock tang, rotate the threaded cable adjuster (1) until 3 threads are showing. 5. Re-check park lock operation. If park lock does not function, fine tune the cable 1/2 turn at a time until the proper operation is achieved. Page 1737 Camshaft Position (CMP) Actuator Solenoid Valve - Intake (LAT) Camshaft Position (CMP) Actuator Solenoid Valve - Intake (LE5 or LE9) Page 9028 Sun Visor: Service and Repair Sunshade Replacement Sunshade Replacement Locations Steering Mounted Controls Transmitter: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 1855 Page 9575 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. Page 8266 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors Yazaki Connectors Special Tools J-38125 Terminal Repair Kit Page 9691 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 2895 If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the Page 7519 Compressor Clutch: Service and Repair Air Conditioning Clutch Assembly Replacement Special Tools * J 37872 Universal Spanner Wrench * J 6083 Snap Ring Pliers * J 39400-A Halogen Leak Detector Removal Procedure 1. Remove the drive belt from the A/C compressor. Refer to Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair) for the 2.4L engine or Drive Belt Replacement (See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair) for the 3.6L engine. 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the lower air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement (See: Engine, Cooling and Exhaust/Cooling System/Radiator/Service and Repair/Removal and Replacement/Radiator Air Lower Baffle and Deflector Replacement). Note: Remove the 3 adjustable dowels from J 37872. Install three 5/16 x 1 inch bolts in place of the dowels. 4. Remove and discard the compressor clutch plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. Specifications Thermostat: Specifications Thermostat Diagnosis In order to inspect if the thermostat valve is opening properly, perform the following test: 1. Completely submerge the thermostat in a glycol solution. The solution should be 11°C (22°F) above the temperature indicated on the thermostat valve. 2. Thoroughly agitate the solution. Under these conditions, the thermostat valve should open. In order to inspect if the thermostat valve is closing properly, perform the following test: 1. Completely submerge the thermostat in a glycol solution. The solution should be 6°C (10°F) below the temperature indicated on the thermostat valve. 2. Thoroughly agitate the solution. Under these conditions, the thermostat valve should close completely. Page 1518 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Page 8391 Disclaimer Page 9166 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. JST Connectors JST Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Page 8280 same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 397 Air Bag Control Module: Locations SIR Identification Views The SIR Identification Views shown below illustrate the approximate location of all SIR components available for the vehicle. This will assist in determining the appropriate SIR Disabling and Enabling for a given service procedure, refer to SIR Disabling and Enabling (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Malibu or Maxx 1 - Right Front Impact Sensor-Located under the hood at the front right side of the vehicle 2 - Front Hood Assist Rod-A gas shock located under the front hood on the passenger side 3 - Passenger Instrument Panel Air Bag-Located at the top right under the instrument panel 4 - Right Roof Rail Air Bag-Located under the headliner, extending from the passenger front windshield pillar to the passenger rear windshield pillar 5 - Right Front Side Impact Sensor (SIS)-Located behind door panel on the passenger front door 6 - Inflatable Restraint Sensing and Diagnostic Module (SDM)-Located underneath the vehicle carpet under the center console 7 - Passenger Seat Side Air Bag-Located on the seat back of passenger seat 8 - Passenger Seat Belt Retractor Pretensioner-Located under the trim near the bottom of the center pillar on the passenger side of vehicle 9 - Inflator Module for Right Roof Rail Air Bag-Located behind the garnish molding on the upper rear pillar 10 - Rear Hood Assist Rod-A gas shock located under the rear truck lid on the passenger side 11 - Rear Hood Assist Rod-A gas shock located under the rear truck lid on the driver side 12 - Inflator Module for Left Roof Rail Air Bag-Located behind garnish molding on the upper rear pillar 13 - Driver Seat Belt Retractor Pretensioner-Located under the trim near the bottom of the center pillar on the driver side of vehicle 14 - Driver Seat Side Air Bag-Located on the seat back of driver seat 15 - Left Front Side Impact Sensor (SIS)-Located behind door panel on the driver front door 16 - Left Roof Rail Air Bag-Located under the headliner, extending from the driver front windshield pillar to the driver rear windshield pillar 17 - Driver Steering Wheel Air Bag-Located on the steering wheel 18 - Front Hood Assist Rod-A gas shock located under the front hood on the driver side 19 - Vehicle Battery-Located at the front left of the engine compartment 20 - Left Front Impact Sensor-Located under the hood at the front left side of the vehicle Passenger Compartment/Roof Component Views Roof/Headliner and Under the Center Console Components Page 5876 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Page 5312 Fuse 6 .................................................................................................................................................. ............... Park Lamps, Instrument Panel Dimming Fuse 7 ................................................................. ................................................................................................................................................. Not Used Fuse 8 ........................................................................................................................................ .......................................................................... Not Used Fuse 9 ....................................................... ........................................................................................................................................................... Not Used Fuse 10 ................................................................................................................................ .................................................................... Sunroof Controls Fuse 11 ............................................... .............................................................................................................................................................. ... Not Used Fuse 12 ............................................................................................................................ .................................................................................... Not Used Fuse 13 ........................................... .......................................................................................................................................................... Audio Amplifier Fuse 14 ...................................................................................................................... ....................................................................... Heated Seat Controls Fuse 15 .................................... .............................................................................................................................................................. .............. Not Used Fuse 16 ..................................................................................................................... Remote Keyless Entry (RKE) System, XM Satellite Radio, UGDO Fuse 17 ........................................................................... ........................................................................................................................... Back-up Lamps Fuse 18 ......................................................................................................................................................... ....................................................... Not Used Fuse 19 ........................................................................ ........................................................................................................................................ Not Used Fuse 20 ................................................................................................................................................ ........................................ Auxiliary Power Outlets Fuse 21 ................................................................ ................................................................................................................................................ Not Used Fuse 22 ...................................................................................................................................... .................................................................. Trunk Release Fuse 23 .................................................... ......................................................................................................................................................... Rear Defog Fuse 24 ............................................................................................................................ ........................................................................... Heated Mirrors Fuse 25 ........................................... .............................................................................................................................................................. ..... Fuel Pump RELAYS .............................................................................................................................................. .................................................................... USAGE Relay 26 .............................................................................................................................................. ......................................... Rear Window Defogger Relay 27 .............................................................. ............................................................................................................................................ Park Lamps Relay 28 ................................................................................................................................... ........................................................................... Not Used Relay 29 .................................................. ............................................................................................................................................................ Not Used Relay 30 .............................................................................................................................. ................................................................................ Not Used Relay 31 ............................................. .............................................................................................................................................................. ... Not Used Relay 32 .......................................................................................................................... .................................................................................... Not Used Relay 33 ......................................... ............................................................................................................................................................. Back-up Lamp Relay 34 ...................................................................................................................... ........................................................................................ Not Used Relay 35 ..................................... .............................................................................................................................................................. ........... Not Used Relay 36 .................................................................................................................. .................................................................................... Trunk Release Relay 37 ................................. .............................................................................................................................................................. ............. Fuel Pump Relay 38 .............................................................................................................. ............................................................................. (Diode) Cargo Lamp Page 4376 15. Align the following items while latching: * The halfshaft inboard seal * The tripot housing (2) * The large seal retaining clamp (3)-Crimp the seal retaining clamp with J 35910 to 176 Nm (130 lb ft). Add the breaker bar (5) and the torque wrench (4) to J 35910 if necessary. 16. Check the gap dimension (a) on the clamp ear. If the gap dimension is larger than shown, continue tightening until the gap dimension of 2.6 mm (0.102 in) is reached. 17. Fully stroke the joint several times to disperse the grease. Page 9710 * Diagnostic probe tool * Terminal release tool * Terminal/terminated lead part numbers Note: Not using the proper test kit probe may cause damage to the terminal(s) that are probed. 2. Determine if a terminal is damaged. * Locate the diagnostic probe tool from the connector end view. The connector end view describes the color and part number to help the technician find and use the correct tool. * Connect the probe tool to the Digital Multimeter. * Insert the probe tool into the cavity and follow the procedures from the Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter). 3. Disconnect the connector body to perform the repair. 4. Use the following procedure to remove the terminal from the connector body. Note: Several procedures for specific connector bodies are called out in the Wiring Repairs section. * The terminal position assurance (TPA) and connector position assurance (CPA) should be removed before releasing the terminal for the connector body. * Look at the connector end view to locate the cavity of the damaged terminal and find the proper terminal release tool from the terminal release tool kit. Note: Using the incorrect terminal release tool can damage the connector body. Note: Some terminals have a lever that must be disengaged before the terminal can be released. * Insert the terminal release tool into the cavity. 5. Gently pull the wire out of the back of the connector. 6. Repair the terminal by following the Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) procedure. 7. Insert the repaired terminal back into the cavity. Repeat the diagnostic procedure to verify the repair and reconnect the connector bodies. Terminated Lead Repair Terminated Lead Repair Special Tools Page 5642 Audio Amplifier X2 (UQ3) Page 9265 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Page 2515 Note: After adjusting the switch, verify the engine only starts in Park or Neutral. If the engine starts in any other position, adjust the switch. 8. Connect the transaxle range switch electrical connectors. 9. Install the shift control cable to transaxle range switch lever and verify proper operation. 10. Install the shift control cable to transaxle range switch lever and verify proper operation. Installation Procedure (New Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Page 4832 4. Ensure the brake pad hardware mating surfaces (1) are clean. 5. Install the brake pad retainers (2) to the brake caliper bracket. 6. Install the brake pad retainers to the disc brake caliper bracket. 7. Install the brake pads to the brake caliper bracket. 8. Install the brake caliper to the mounting bracket. 9. Apply a thin coat of high temperature silicone lube to the brake caliper guide pins. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 10. Install the brake caliper guide pin bolts and tighten to 35 Nm (26 lb ft). 11. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 12. Lower the vehicle. 13. Fill the master cylinder to the proper level. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). Rear Brake Caliper Hardware Replacement Rear Brake Caliper Hardware Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Caution: When using a large C-clamp to compress a caliper piston into a caliper bore of a caliper equipped with an integral park brake mechanism, do not exceed more than 1 mm (0.039 in) of piston travel. Exceeding this amount of piston travel will cause damage to the internal adjusting mechanism and/or the integral park brake mechanism. 4. Using a C-clamp installed to the center of the outer brake pad and the back of the caliper, slowly compress the caliper piston into its bore just enough to remove the caliper from the mounting bracket. Do not exceed 1 mm (0.039 in) of caliper piston travel. Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Page 2448 1. Install the fuel level sensor (1) to the alignment feature (2). 2. Allow the locking tab (2) to lock into place. 3. Connect the fuel level sensor electrical connector (1). 4. Install the fuel pump module assembly. Refer to Fuel Tank Fuel Pump Module Replacement (See: Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). Page 765 Page 1408 Locations Knock Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Lower Front and Rear of the Engine Components (LY7) Page 3082 Page 8665 Page 10729 8. Gently depress the windshield on the auto-adhesive bead until the windshield is seated 1 mm (0.039 in) below the roof. 9. Use masking tape (1) to hold the window (2) in the position until the auto-adhesive completely cures. 10. Make sure to observe the auto- adhesive curing time before releasing the vehicle per autoinstructions by the manufacturer's. Note: Following the auto-adhesive installation instructions, using nifty to remove any excess of auto-adhesive within 30 minutes, otherwise it will not be possible to remove the auto-adhesive excess unless using mechanical means. 11. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. Note: Do not direct a hard stream of high pressure water to the freshly applied auto-adhesive. 12. Use a soft spray of warm water in order to immediately water test the windshield. 13. Inspect the windshield for leaks. 14. If any leaks are found, use a plastic paddle in order to apply extra auto-adhesive at the leak point. 15. Retest the windshield for leaks. 16. Maintain the following conditions in order to properly cure the auto-adhesive: * Partially lower a door window in order to prevent pressure buildups when closing doors before the auto-adhesive cures. * Do not use compressed air in order to dry the auto-adhesive. Page 6937 Page 5200 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 9661 1. Locate the assist lever on the top of the connector. Move the assist lever to the forward position. 2. Disconnect the connector from the component. Page 6254 Door Latch - Right Rear Page 8763 Front Door Weatherstrip: Service and Repair Front Side Door Upper Auxiliary Sealing Strip Replacement Front Side Door Upper Auxiliary Sealing Strip Replacement Page 2432 Coolant Temperature Sensor/Switch (For Computer): Diagrams Component Connector End Views Engine Coolant Temperature (ECT) Sensor (LAT or LE5 or LE9) Engine Coolant Temperature (ECT) Sensor (LY7) Locations Ambient Light Sensor: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 3594 Note: Rotate the pigtail 90 degrees from vertical before securing the fastener. 1. Install the knock sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the knock sensor bolt and tighten to 25 Nm (18 lb ft). 3. Install the knock sensor electrical connector pigtail (6) clip to the oil level indicator tube bracket. 4. Connect the engine wiring harness electrical connector (1) to the knock sensor pigtail electrical connector (6). 5. Lower the vehicle. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Service and Repair Air Bag Deactivation Indicator: Service and Repair Inflatable Restraint Instrument Panel Module Indicator Replacement Page 7333 Disclaimer Page 6914 Note: Start all of the nuts and bolts by hand before finalizing any of the torques. 1. Install the NEW steering gear oil seals (1) to the steering gear using the J-44586 remover/installer (2). 2. Ensure the steering gear oil seals (1) are fully seated in the steering gear. Caution: The inlet and outlet hoses must not be twisted during installation. Do not bend or distort the inlet or outlet hoses to make installation easier. Failure to follow these procedures could result in component damage. 3. Position the power steering gear outlet hose to the vehicle. 4. Install the steering gear. Refer to Steering Gear Replacement (See: Steering Gear/Service and Repair/Steering Gear Replacement). Electrical - Various Electrical Systems Malfunctions Body Control Module: Customer Interest Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Page 420 Steering Control Module: Diagrams Component Connector End Views Electric Power Steering (EPS) Module X1 (without NVH) Electric Power Steering (EPS) Module X2 (without NVH) Page 5741 Fuse Block - Underhood Top View (LE5 or LE9) Page 2520 1. Install the O-ring onto the VSS. 2. Install the output VSS into the transmission case. Caution: Refer to Fastener Caution 3. Install the VSS stud and tighten the stud to 12 Nm (106 lb in). 4. Install the VSS electrical harness retainer to the VSS stud. 5. Connect the VSS electrical connector. 6. Lower the vehicle. Door Lock Switch Replacement - Driver Door Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Driver Door Door Lock Switch Replacement - Driver Door Campaign - Airbag Readiness Light/Service Airbag Message Technical Service Bulletin # 10085D Date: 110203 Campaign - Airbag Readiness Light/Service Airbag Message CUSTOMER SATISFACTION Bulletin No.: 10085D Date: February 03, 2011 Subject: 10085D - Airbag Readiness Light/Service Airbag Message - Replace Connectors Models: 2008 Buick Enclave 2010 Chevrolet Malibu 2008 GMC Acadia 2010 Pontiac G6 2008 Saturn OUTLOOK Supercede: The Service Procedure in this bulletin has been revised. All vehicles will not require the replacement of the front seat-mounted side impact airbag connectors.Please discard all copies of bulletin 10085C, issued November 2010. Condition Certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may experience wear which could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact air bag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG System warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG System DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Correction Dealers are to replace the front seat-mounted side impact airbag connectors. Vehicles Involved Involved are certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Part Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your Page 8646 Disclaimer Page 6030 * In some cases Delphi will actually be printed on the connector. If Delphi is not printed on the connector, look for PED. In both cases there is no specific orientation for Delphi or PED and they can appear anywhere on the connector. * FCI connectors may have the FCI logo on their connectors. The logo is the letters FCI with an "A" above it. Page 10109 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Page 710 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 9338 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement Page 8226 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Page 5704 X500 Inline Harness Connector End Views X500 Body Harness to Left Front Door Harness Page 8572 Page 5174 Page 8768 Front Door Window Glass: Technical Service Bulletins Body - Side Window Chipping Information INFORMATION Bulletin No.: 06-08-64-001B Date: October 20, 2009 Subject: Information on Side Door Window Glass Chipping Caused by Hanging Vehicle Key Lock Box Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add vehicles and model years and to include all types of door window glass. Please discard Corporate Bulletin Number 06-08-64-001A (Section 08 - Body & Accessories). - In several warranty parts review cases, side door window glass was observed with a chip or chips on the top side of the window glass. Dealer contacts confirmed that they use a vehicle key lock box on the front side door window glass. - A random selection of side door glass returns will be conducted to confirm adherence. If a side door glass is discovered with a chip or chips in the location previously described, the side door glass will be returned to the dealership for debit. Example of Side Door Glass - DO NOT place a vehicle key lock box on a side door window glass. Page 9133 Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) * Troubleshooting with a Test Lamp (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Test Lamp) * Using Fused Jumper Wires (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Fused Jumper Wires) * Measuring Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage) * Measuring Voltage Drop (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Voltage Drop) * Measuring Frequency (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Measuring Frequency) * Testing Ground and Low Reference Circuits (See: Testing and Inspection/Component Tests and General Diagnostics/Testing Ground and Low Reference Circuits) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) * Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) * Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) * Circuit Protection - Fuses (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fuses) * Circuit Protection - Circuit Breakers (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Circuit Breakers) * Circuit Protection - Fusible Links (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Circuit Protection - Fusible Links) Troubleshooting with a Test Lamp Troubleshooting with a Test Lamp Special Tools J 35616-200 Test Light - Probe Kit Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). A test lamp can simply and quickly test a low impedance circuit for voltage. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The J 35616-200 is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedures. When testing for voltage: 1. Attach one lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. When testing for ground: 1. Attach one lead to battery positive voltage. 2. Touch the other lead to various points along the circuit where ground should be present. 3. When the bulb illuminates, there is ground at the point being tested. Testing for a Short to Voltage Page 5441 Engine Control Module (ECM) X1 (LY7) Page 1182 Page 2973 Oxygen Sensor: Service Precautions Silicon Contamination of Heated Oxygen Sensors Caution Silicon Contamination of Heated Oxygen Sensors Caution Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor. Heater Inlet Hose Replacement Heater Hose: Service and Repair Heater Inlet Hose Replacement Heater Inlet Hose Replacement Special Tools J 38185 Hose Clamp Pliers Warning With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. Removal Procedure 1. Partially drain the coolant. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). 2. Remove the surge tank from the surge tank bracket. 3. Reposition the heater inlet hose clamp at the heater core using the J 38185. 4. Remove the heater inlet hose from the heater core. Page 16 Central Control Module: Diagrams Component Connector End Views Vehicle Communication Interface Module (VCIM) X1 (UE1) Vehicle Communication Interface Module (VCIM) X2 (UE1) Hood Primary Latch Release Cable Replacement Hood Latch Release Cable: Service and Repair Hood Primary Latch Release Cable Replacement Hood Primary Latch Release Cable Replacement Removal Procedure 1. Open the hood. 2. Remove the upper fascia support. 3. Mark the position of the latch to the body. 4. Remove the hood latch bolts. 5. Disconnect the hood release cable from the hood latch by squeezing the hood release cable retainer. 6. Remove the side trim panel retainers. 7. Remove the hush panel from the instrument panel. 8. Remove the knee bolster from the instrument panel. 9. Remove the hood latch release cable handle bolts. Note: Ensure the end of the wire or string remains in the passenger compartment. 10. Tie the wire or string to the end of the hood release cable in order to aid in the installation of the new hood release cable. 11. Remove the grommet from the engine compartment into the passenger compartment using a small flat-bladed tool. 12. Remove the hood release cable from the instrument panel. Page 10462 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 8510 Speaker - Left Front Tweeter Speaker - Left Rear (UQA) Locations Fog/Driving Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (except LAT) Page 3776 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 3458 Page 1755 6. Install the camshaft bearing caps. Hand tighten the cap bolts. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 7. Tighten the bearing cap bolts in increments of 3 turns until they are seated. Tighten the bolts to 10 Nm (89 lb in). 8. Install the intake camshaft position actuator. Refer to Camshaft Position Intake Actuator Replacement (See: Camshaft Position Intake Actuator Replacement). Page 8700 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Extension Replacement Rear Bumper Fascia Extension Replacement Procedures Windshield: Procedures Windshield Glass Cleaning Clean the windshield with windshield cleaner, or equivalent. The cleaner should not harm the paint finish or scratch the glass. The glass is clean when the water no longer beads, but sheets across the entire glass surface. Page 5575 Seat Vertical Motor - Driver (without LTZ and AG1) Secondary Air Injection (AIR) Pump (NU6) Page 9945 1. While depressing the lock, twist and remove the connector from the component. 2. Locate the terminal position assurance (TPA). Page 5547 Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LZ4 or LZE) Page 6517 X301 Inline Harness Connector End Views X301 Body Harness to the Automatic Transmission Shift Lock Control Solenoid X303 Inline Harness Connector End Views X303 Console Jumper Harness to Console Harness Page 6258 Electric Power Steering (EPS) Module X2 (without NVH) Page 9684 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors Yazaki Connectors Special Tools J-38125 Terminal Repair Kit Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 6358 Inflatable Restraint Side Impact Module - Right Inflatable Restraint Side Impact Sensor (SIS) - Left Page 94 Warranty Information (Saab U.S. Models) Disclaimer Page 7932 Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Owner Letter Owner Letter March 2011 Page 9511 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Page 1768 Note: * The camshaft actuators should not rotate during the removal or installation. * Ensure the tips of the EN-48749 - retention tool are fully engaged into the timing chain. The retention tool rod can be used on the back side of the chain to ensure the teeth from the retention tool are engaged. 11. Install the EN-48749 - retention tool (1) to the exhaust side of the timing chain. 12. Remove and discard the exhaust camshaft actuator bolt (2). 13. Remove the exhaust camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain. Installation Procedure Page 1986 7. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Ensure the timing chain tensioner seal is centered throughout the torque procedure to eliminate the possibility of an oil leak. 8. Install the timing chain tensioner assembly. Tighten the timing chain tensioner to 75 Nm (55 lb ft). 9. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner. 10. Install the camshaft cover. Refer to Camshaft Cover Replacement (See: Cylinder Head Assembly/Valve Cover/Service and Repair). 11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Page 6433 Throttle Body Page 2118 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 268 Disclaimer Page 3952 Specifications Camshaft Gear/Sprocket: Specifications Exhaust Camshaft Position Actuator First Pass ............................................................................................................................................. ......................................................... 30 Nm (22 lb ft) Final Pass ........................................................ .................................................................................................................................................... 100 degrees Intake Camshaft Position Actuator First Pass ............................................................................................................................................. ......................................................... 30 Nm (22 lb ft) Final Pass ........................................................ .................................................................................................................................................... 100 degrees TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 5213 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wire dress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. A/C - Poor Cooling Performance/Condenser Fan Fuse Blown Condenser Fan: Customer Interest A/C - Poor Cooling Performance/Condenser Fan Fuse Blown TECHNICAL Bulletin No.: 09-01-38-005 Date: October 09, 2009 Subject: Poor A/C Performance, Cooling Fan Fuse Blown (Install Revised Fuse And Wiring) Models: 2008-2010 Chevrolet Malibu 2006-2010 Pontiac G6 2007-2010 Saturn AURA All with RPO LY7, LZ4, LZ9 or LZE V6 Engine Condition Some customers may comment on poor A/C cooling performance. Technicians may find that the cooling fan fuse is blown. Cause High cooling fan start up loads may cause the 30-amp cooling fan fuse, located in the underhood fuse block, to blow. The lack of air flow through the A/C condenser, caused by the inoperative high-speed cooling fan, may affect the condenser's ability to dissipate heat. Correction Use the following procedure to install a heavier gauge power feed wire from the underhood fuse block to the cooling fan. After the wiring update is completed, replace the 30-amp cooling fan fuse in the underhood fuse block with a 40-amp fuse. 1. Disconnect and remove the battery. Refer to Battery Replacement in SI. 2. Remove the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 3. Disconnect the underhood fuse block from it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. It is only necessary to raise the fuse block enough to access the harness connectors. Do not remove the complete assembly from the vehicle. 4. Locate the engine wiring harness junction block assembly (X1) on the back (underside) of the underhood fuse block and disconnect it from the underhood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 5. Find pin A2, Circuit 532, cooling fan motor supply voltage. Refer to Electrical Center Identification Views, Fuse Block-Underhood X1 in SI. 6. Remove the harness back cover. Remove the TPA (terminal position assurance) clip and remove connector A2 from the junction block. Cut the terminal off and tape the wire end with electrical tape. 7. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 8. Locate the electrical connector to the right cooling fan and disconnect the wiring connector from the fan. 9. Disengage pin B, wire 3 GY, circuit 532, cooling fan motor supply voltage, from the connector housing (pull to seat terminal). Cut the terminal off of the wire and remove the wire from the connector housing. 10. Tape the end of the wire with electrical tape. 11. Prepare a 1.82 m (6 ft) section of automotive grade 5.0 mm (10 GA) wire and an equal length of 6 mm (1/4 in) flexible plastic conduit, GM P/N 12051375. 12. Run the new wire through the fan wire connector housing as shown. 13. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 14. Strip the wire insulation as required and install the terminal, GM P/N 12033997, on the wire. Secure the wire and terminal into the fan wire Page 9288 Page 8822 Rear Door Window Glass: Service and Repair Rear Side Door Stationary Window Replacement Rear Side Door Stationary Window Replacement Page 6641 6. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals on to the bare wire using the J38125-7 crimp tool, jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 7. Position the wire seal to the terminal and crimp the seal and insulation using the J-38125-6 crimp tool, jaw 1 (1). The completed terminal and seal should appear as shown above (body harness connector shown). Note Avoid getting solder on the terminal end or overheating the terminal. Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. 8. Solder all four terminals at the wire crimp. 9. Slide the two body harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Page 5568 Seat Belt Pretensioner - Passenger Page 10736 Page 4309 Input Speed Sensor Seal Replacement Page 9087 Page 4406 6. Remove the wheel bearing/hub mounting bolts (1). 7. Remove the wheel bearing/hub and backing plate from the steering knuckle. Page 9093 Page 4667 Page 3554 Note: Rotate the pigtail 90 degrees from vertical before securing the fastener. 1. Install the knock sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the knock sensor bolt and tighten to 25 Nm (18 lb ft). 3. Install the knock sensor electrical connector pigtail (6) clip to the oil level indicator tube bracket. 4. Connect the engine wiring harness electrical connector (1) to the knock sensor pigtail electrical connector (6). 5. Lower the vehicle. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Page 5810 Note DO NOT replace the sensing and diagnostic module (SDM), side sensors or air bag modules. Note Both driver and passenger seats must be repaired when this concern occurs even if only one DTC code is set. The service kit contains sufficient components to repair both seat connectors. Connector Replacement Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above includes harness and connector clips, which are not required in this installation. Replace connectors on both driver and passenger seats, and then reposition the connectors following the steps below. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Note Only use hand tools to remove the seat to floor mounting bolts. If there are any problems with bolt removal, refer to Corporate Bulletin Number 10-08-50-002. 2. Remove the driver's seat to floor mounting bolts. Loosen the seat from the front retainers and tilt it back to expose the underside of the seat. Refer to Front Seat Replacement - Bucket in SI. Page 1309 Fluid - A/T: Fluid Type Specifications Automatic Transmission DEXRON-VI Automatic Transmission Fluid. Page 4637 3 - Torque Converter Assembly 4 - Manual Shaft and Detent Lever Assembly 5 - 2nd Clutch 6 Reverse Clutch 7 - Coast Clutch 8 - Direct Clutch 9 - Reaction Planetary Gear Set 10 - Input Planetary Gear Set 11 - Forward Clutch 12 - Lo Roller Clutch 13 - Parking Lock Actuator Assembly 14 - Differential and Final Drive Assembly 15 - Output Stub Shaft 16 - Output Speed Sensor 17 Lo/Reverse Servo Assembly 18 - Lo/Reverse Band 19 - Oil Feed Tube Assembly 20 - Input Sprag Clutch Assembly 21 - Oil Filter Assembly 22 - 2nd Roller Clutch 23 - Oil Level Control Valve 24 Drive Link Assembly 25 - Driven Sprocket 26 - Output Shaft 27 - Channel Plate Assembly 28 Input Speed Sensor 29 - 4-3 Solenoid 30 - Drive Sprocket 31 - Control Valve Body Assembly 32 Oil Pump Assembly 33 - Auxiliary Pump Disassembled Views Disassembled Views Case and Associated Parts Page 8847 10. Install the side trim panel. 11. Install the hush panel to the instrument panel. Page 5955 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 818 Intake Air Temperature Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 229 Fuse Block - Underhood Top View (LZ4 or LZE) Page 9115 Page 1796 6. Hold the threaded shaft of the EN 45680-882 cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve. 7. Install the EN 456850-881 fixture (4) onto the threaded shaft of the EN 456850-882 cylinder bore sleeve puller and the engine block. 8. Install the bearing (3) and the nut (1). 9. Tighten the nut (1) to the bearing (3). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Use 4 old cylinder head bolts for the attaching bolts. 10. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten the bolts to 15 Nm (11 lb ft). 11. Rotate the nut clockwise in order to remove the cylinder bore liner. Page 2121 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor (1) from the thermostat housing. Installation Procedure Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, Page 9467 Page 5940 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. Page 5187 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Page 7986 Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information 1. Submit a transaction using the table below. * The amount identified in the Net Item column should represent the actual cost of the woven polyester electrical tape, required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a customer satisfaction program that affects your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle. Page 5117 Starter Motor X2 (Starter to Generator) (LY7 or LZ4 or LZE) Page 2766 Engine Control Module (ECM) X3 (LAT) Electrical - Various Electrical Systems Malfunctions Body Control Module: All Technical Service Bulletins Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Page 8671 Body Control Module: Service and Repair Body Control Module Replacement Page 9605 Page 9466 Page 4407 Installation Procedure 1. Position the backing plate and wheel bearing/hub assembly in the steering knuckle. Page 7803 Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a Customer Satisfaction Program that affects your 2010 model year Chevrolet Malibu or Pontiac G6. We have learned that your 2010 model year Chevrolet Malibu or Pontiac G6 may have a condition in which wear could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact airbag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG system warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG system DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Your Malibu or G6 may have been serviced previously to reroute and secure both front seat-mounted side impact airbag wire harnesses. However, there have been reports of the SERVICE AIR BAG message illuminating in the Driver Information Center (DIC) on vehicles that had the wire harnesses rerouted and secured, but did not have new connectors installed. Our records indicate that your vehicle may not have had the new connectors installed. What We Will Do: Since your vehicle may not have had new connectors installed, your GM dealer will inspect your vehicle to determine if new connectors have been installed, and will install two new connectors, if required. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 11034 Page 8571 Accessory Power Outlet - Center Console Page 179 Page 9262 Page 4303 Automatic Transmission Output Shaft Speed (OSS) Sensor (ME7 or MN5) Page 9968 same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. A/T Controls - Downshift Hesitation/Delayed Shifting Control Module: Customer Interest A/T Controls - Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 1457 Relay Box: Locations Fuse Block - Rear Electrical Center Identification Views Fuse Block - Rear Label Steering - Front End Clunk/Rattle/Knock On Bumps Strut Mount: All Technical Service Bulletins Steering - Front End Clunk/Rattle/Knock On Bumps TECHNICAL Bulletin No.: 06-02-32-007G Date: April 05, 2010 Subject: Clunk, Knock or Rattle Noise From Front of Vehicle While Driving or Turning Over Bumps at Low Speeds (Diagnose Noise and Perform Outlined Repair) Models: 2004-2006 Chevrolet Malibu Maxx 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn Aura Supercede: This bulletin is being revised to update the Parts Information for the bolt. Please discard Corporate Bulletin Number 06-02-32-007F (Section 02 - Steering). Condition 1 Some customers may comment on a clunk noise heard and felt in the steering wheel while driving at slow speeds and turning. The clunk noise may appear to be directly in front of the driver. Hitting a bump while turning can produce the clunk noise. Sometimes the noise may be duplicated when the vehicle is sitting still and the steering wheel is turned 90 degrees in either direction before initially centering the steering wheel. Cause 1 The clunk noise may be caused by a slip/stick condition between the inner and outer components of the intermediate shaft. Important Revised design intermediate shafts went into production in the 2009 model year and are the only design currently available through GMSPO since approximately September 2008. Since any model year vehicle could have had a second design shaft installed, it is critical to identify it before proceeding. The revised design intermediate shafts will NOT tolerate any type of lubricant per the following instructions. Adding lube to the second design shafts will cause a clunk noise in a very short period of time. Use the following pictures to identify which design of shaft you are servicing. Electric Assist Power Steering First Design - Bare Steel Tube (Lube OK) Locations Fuse Block: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 9825 Air Dam: Service and Repair Front Air Deflector Replacement Front Air Deflector Replacement Page 6383 Park/Turn Signal Lamp - Right Page 4226 Page 4858 1. Align the brake fluid level sensor to the master cylinder reservoir. 2. Press the brake fluid level sensor into the master cylinder reservoir, ensure the retaining tabs click into place. 3. Connect the electrical connector to the brake fluid level sensor. Page 5426 Door Lock Switch - Driver Page 10004 Page 6533 X500 Inline Harness Connector End Views X500 Body Harness to Left Front Door Harness Page 5918 For vehicles repaired under warranty, use the table. Disclaimer Page 2827 Page 8583 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Page 5985 Locations Washer Fluid Level Switch: Locations Front of Vehicle/Engine Compartment Component Views Front and Right Rear of the Engine Compartment Components 1 - A/C Refrigerant Pressure Sensor 2 - Engine Cooling Fan - Right 3 - Engine Cooling Fan - Left 4 - Windshield Washer Fluid Pump 5 - Windshield Washer Fluid Level Switch 6 - Horn Assembly Page 9098 Locations Manifold Pressure/Vacuum Sensor: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) Page 2972 Oxygen Sensor: Service Precautions Heated Oxygen Sensor Resistance Learn Reset Caution Heated Oxygen Sensor Resistance Learn Reset Caution Caution: When replacing the HO2S perform the following: * A code clear with a scan tool, regardless of whether or not a DTC is set * HO2S heater resistance learn reset with a scan tool, where available Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure. Page 6012 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Page 8690 Page 4113 Input Speed Sensor Seal Replacement Page 2690 Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If reinstalling the original sensor, or if installing a NEW sensor without a sealer, coat the threads with sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor (1) to the thermostat housing and tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Page 2112 Page 6846 Steering Angle Sensor: Diagrams Component Connector End Views Steering Wheel Position Sensor (NVH) Page 1619 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 248 Page 5463 Engine Oil Pressure (EOP) Switch (LY7) Evaporative Emission (EVAP) Canister Purge Solenoid Valve (LAT or LE5 or LE9) Page 2902 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of a connector. CPAs are used in all SIR System connectors and also in some connectors of other systems. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of a connection. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Sleeves Splicing Copper Wire Using Splice Sleeves Special Tools J-38125 Terminal Repair Kit Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Page 1812 1. Install the coolant heater. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the coolant heater bolt and tighten to 10 Nm (89 lb in). 3. Connect the coolant heater cord. 4. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair). Page 2805 Page 4363 4. Install the outer CV joint assembly in a vise. Important: The following procedure will have to be repeated until all the ball bearing are removed form the cage. 5. Using a brass drift (1), gentle tap the cage until the ball bearing can be removed from the cage. 6. Using a small screwdriver, remove the ball bearings from the CV joint. 7. Position the CV joint housing (2) so they are level. Page 5196 6. Release the rear lower half of the wire dress cover. 7. Release the tabs that are holding the wire dress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Page 9939 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wire dress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 5316 Body Control Module (BCM) Bottom View Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder Replacement Page 3873 Band Apply Servo: Service and Repair Intermediate/Fourth Servo Assembly Replacement Intermediate/Fourth Servo Assembly Replacement Removal Procedure 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the oil pan and filter. Refer to Automatic Transmission Fluid Filter and Seal Replacement (See: Fluid Filter - A/T/Service and Repair). 3. Remove the two intermediate/4th servo cover bolts, the servo and the spring. Disassemble Procedure 1. Remove the piston and pin assembly (76 and 77) from the servo cover (80). 2. Remove the snap ring (70) from the servo pin (76). 3. Remove the piston (77) and the servo cushion springs (68) from the servo pin (76). 4. Remove the servo piston seals (78, 79) from the servo cover (80). 5. Discard the servo piston seals (78 and 79). Do not reuse the servo piston seals. Page 10045 Page 7144 1. Connect the stabilizer link to the strut assembly and tighten to 65 Nm (48 lb ft). 2. Connect the stabilizer link to the stabilizer shaft and tighten to 65 Nm (48 lb ft). 3. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 4. Lower the vehicle. Page 1581 Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 9557 Removal Procedure 1. While depressing the lock, pull the two connector halves apart. Note: The TPA is fragile and may break if not done carefully. 2. Use a small flat-blade tool to very carefully push the terminal position assurance (TPA) towards the face of the connector on both sides of the connector. 3. View of the male half of the connector with female terminals. Page 4143 Page 7821 Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a Customer Satisfaction Program that affects your 2010 model year Chevrolet Malibu or Pontiac G6. We have learned that your 2010 model year Chevrolet Malibu or Pontiac G6 may have a condition in which wear could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact airbag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG system warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG system DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Your Malibu or G6 may have been serviced previously to reroute and secure both front seat-mounted side impact airbag wire harnesses. However, there have been reports of the SERVICE AIR BAG message illuminating in the Driver Information Center (DIC) on vehicles that had the wire harnesses rerouted and secured, but did not have new connectors installed. Our records indicate that your vehicle may not have had the new connectors installed. What We Will Do: Since your vehicle may not have had new connectors installed, your GM dealer will inspect your vehicle to determine if new connectors have been installed, and will install two new connectors, if required. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 11034 Page 4677 15. Remove the BPMV bolt (1). 16. Remove the BPMV from the bracket (1). 17. Inspect the BPMV bracket insulator for damage and replace, if necessary. 18. If installing a new BPMV, remove the EBCM. Refer to Electronic Brake Control Module Replacement (See: Electronic Brake Control Module/Service and Repair). Installation Procedure Note: When installing a new BPMV, do NOT remove the shipping plugs from the pipe ports until after installation into the vehicle. 1. Install the EBCM, if removed. Refer to Electronic Brake Control Module Replacement (See: Electronic Brake Control Module/Service and Repair). Page 2419 Camshaft Position (CMP) Sensor - Bank 2 Intake (LY7) Page 5318 Restraints - Air Bag Lamp ON/Multiple DTC Set Air Bag Control Module: All Technical Service Bulletins Restraints - Air Bag Lamp ON/Multiple DTC Set TECHNICAL Bulletin No.: 08-09-41-002F Date: June 10, 2010 Subject: Diagnostic Information for Supplemental Inflatable Restraint (SIR) System, Intermittent AIR BAG Indicator/Lamp Illuminated with DTC(s) B0012, B0013, B0015, B0016, B0019, B0020, B0022, B0023, B0026, B0033, B0040, B0042 or B0044 Set (Inspect and Replace Connector Position Assurance (CPA) Retainer) Models: 2005-2007 Buick Rainier 2006-2009 Buick Allure (Canada only), LaCrosse, Lucerne 2008-2010 Buick Enclave 2006-2010 Cadillac DTS 2007-2010 Cadillac Escalade Models 2008-2009 Cadillac SRX, XLR 2008-2010 Cadillac CTS, STS 2005-2006 Chevrolet SSR 2005-2009 Chevrolet TrailBlazer, TrailBlazer EXT 2005-2010 Chevrolet Cobalt 2006-2007 Chevrolet Monte Carlo 2006-2010 Chevrolet Corvette, HHR, Impala, Malibu Models (includes Malibu Classic) 2007-2009 Chevrolet Equinox 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Express 2009-2010 Chevrolet Traverse 2005-2009 GMC Envoy Models 2007-2010 GMC Acadia, Sierra, Yukon, Yukon Denali, Yukon XL, Yukon Denali XL 2008-2010 GMC Savana 2005-2006 Pontiac Pursuit 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Pontiac G5, Torrent 2008-2009 Pontiac G8 2005-2009 Saab 9-7X 2007-2009 Saturn AURA, OUTLOOK, SKY 2008-2009 Saturn VUE 2008-2009 HUMMER H2 2007-2008 Daewoo G2X 2007-2009 Opel GT Supercede: This bulletin is being revised to update the Warranty Information and add Saab Warranty Information. Please discard Corporate Bulletin Number 08-09-41-002E (Section 09 Restraints). Condition - Some customers may comment on an intermittent or current AIR BAG indicator or lamp being illuminated on the instrument panel cluster (IPC). Important This bulletin only applies to the following DTCs: - Technicians may observe DTC(s) B0012 04, 0D, 0E; B0013 04, 0D, 0E; B0015 04, 0D, 0E; B0016 04, 0D, 0E; B0019 04, 0D, 0E; B0020 04, 0D, 0E; B0022, B0023 04, 0D, 0E; B0033 04, 0D, 0E; B0040 04, 0D, 0E; B0042 or B0044 set as Current or in History in the sensing and diagnostic module (SDM). Cause This condition may be caused by a loose, missing, or damaged connector position assurance (CPA) retainer at a supplemental inflatable restraint (SIR) module electrical connector, or a deployment loop wiring harness electrical connector. Correction Page 2009 7. Remove and discard the engine front cover gasket. Installation Procedure 1. Install a NEW engine front cover gasket to the dowel pins. 2. Install the engine front cover. Page 8385 Disclaimer Page 4204 7. Install the transmission range selector lever cable (2) to the cable bracket. 8. Connect the transmission range selector lever cable terminal (1) to the transmission manual shift lever pin. 9. Adjust the automatic transmission range selector lever cable. Refer to Range Selector Lever Cable Adjustment (See: Adjustments/6T30/6T40/6T45 - Automatic Transmission). Range Selector Lever Cable Bracket Replacement Range Selector Lever Cable Bracket Replacement Removal Procedure 1. Set the park brake and chock the wheels. 2. Disconnect the range selector cable end (1) from the range selector lever. 3. Disconnect the range selector cable (2) from the range selector cable bracket. Page 7427 Page 3062 Page 7504 Blower Motor Resistor: Service and Repair Auxiliary Air Conditioning Blower Motor Resistor Replacement Auxiliary Air Conditioning Blower Motor Resistor Replacement Page 4190 5. Slide the two halves (1, 2) of the range select cable together until all free play is removed. 6. Depress the adjuster clip (1) locking the adjuster clip completely. 7. Pull both halves of the range select cable in opposite directions to verify the cable adjuster is secured. 8. Check the transmission range select lever in all gear selections for proper operation. Page 3727 25 - Torque Converter and Support and A/Trans Fluid Pump Housing Assembly 26 - Torque Converter and Differential Housing Bolt 27 - Torque Converter Assembly 28 - Dust Cover Push Pin - Model Dependent 29 - Dust Cover Bolt - Model Dependent 30 - Dust Cover - Model Dependent 31 - Front Differential Carrier Assembly 32 - Input Shaft Thrust Bearing Assembly 33 - A/Trans Case Cover Gasket 34 - A/Trans Case Cover Assembly 35 - A/Trans Case Cover Assembly Bolt A/Trans Case Cover, 2-6 and Low Reverse Pistons 400 - A/Trans Input Speed Sensor Assembly 401 - A/Trans Input Speed Sensor Bolt 402 - ISS O-Ring Seal 403 - A/Trans Case Cover Assembly 404 - 3-5-Reverse and 4-5-6 Clutch Fluid Seal Ring 405 - 2-6 Clutch Piston 406 - 2-6 Clutch Spring Assembly 407 - 2-6 Clutch Spring Retainer Ring 408 - Low and Reverse Clutch Piston Assembly 409 - Low and Reverse Clutch Spring 410 Low and Reverse Clutch Spring Retainer Ring Page 7481 Ambient Temperature Sensor / Switch HVAC: Service and Repair Ambient Air Temperature Sensor Replacement Page 5635 Accessory Power Outlet - I/P Accessory Power Outlet - 110V AC (KV1) Locations Yaw Rate Sensor: Locations Passenger Compartment/Roof Component Views Roof/Headliner and Under the Center Console Components 1 - Inflatable Restraint Roof Rail Module - Right Front 2 - Inflatable Restraint Roof Rail Module Left Front 3 - Yaw and Lateral Accelerometer Sensor 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Page 8181 Page 2250 Heat Shield: Service and Repair Exhaust Manifold Lower Heat Shield Replacement Exhaust Manifold Lower Heat Shield Replacement Removal Procedure 1. Remove the catalytic converter. Refer to Catalytic Converter Replacement - Right Side (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement - Right Side). 2. Remove the exhaust manifold lower heat shield bolts (1, 2). 3. Remove the exhaust manifold lower heat shield. Installation Procedure 1. Position the exhaust manifold lower heat shield to the engine. Page 7319 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Specifications Power Steering Fluid: Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Locations Power Window Switch: Locations Door Component Views Driver Door Components 1 - Door Frame 2 - Outside Rearview Mirror - Driver 3 - Outside Rearview Mirror Switch 4 Courtesy Lamp - Left Front Door 5 - Door Lock Switch - Driver 6 - Window Motor - Driver 7 Speaker - Left Front 8 - Rear Compartment Lid Release Switch 9 - Window Switch - Driver 10 Inflatable Restraint Side Impact Sensor (SIS) - Left 11 - Door Latch - Driver Passenger Door Components Page 2807 Page 10079 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 5235 7. The illustration above identifies the entry canal where the terminal release tool will be inserted, and the terminal cavity. * Terminal (1) * Entry Canal (2) 8. Insert the J 38125-553 tool into the entry canal and pry up on the terminal retainer. The terminal retainer is a small plastic piece on the top of the terminal. The terminal retainer must be held up while the terminal is pulled out of the connector. Page 2849 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 9713 Seat Heater: Electrical Diagrams Heated/Cooled Seat Schematics Driver Seat Passenger Seat Service and Repair Power Steering Pressure Control Valve: Service and Repair Power Steering Pump Flow Control Valve Replacement - Off Vehicle Disassembly Procedure 1. Remove the power steering pump flow control valve fitting (5) from the power steering pump housing (1). 2. Remove the power steering pump flow control valve fitting O-ring seal (4) from the power steering pump flow control valve fitting (5). 3. Remove the power steering pump flow control valve (3). 4. Remove the power steering pump flow control valve spring (2). Assembly Procedure Electrical - Various Electrical Systems Malfunctions Wiring Harness: Customer Interest Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Page 7273 Frequently Asked Questions Disclaimer Page 4064 9. Remove the right hand axle seal from the transmission. Use the J 23129 and the J 6125-1B. Installation Procedure Note: J 41228 must be used in order to install the sleeve to the correct depth. 1. Use J 41228 to install a NEW sleeve on the output axle shaft. 2. Install the collet into the output shaft snap ring groove with the collet attached to the threaded collet shaft. 3. Place the NEW sleeve over the collet. 4. Install the bearing and nut onto the threaded collet shaft. 5. Hold the collet shaft while tightening the nut in order to press the sleeve onto the output shaft. 6. Remove the J 41228. Page 5145 Antilock Brake System Automated Bleed Brake Bleeding: Service and Repair Antilock Brake System Automated Bleed Antilock Brake System Automated Bleed Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning). Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (See: Service Precautions/Vehicle Damage Warnings/Brake Fluid Effects on Paint and Electrical Components Caution). Note: * Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Hydraulic Brake System Bleeding). * The automated bleed procedure must be performed when a new brake pressure modulator valve (BPMV) is installed, because the secondary circuits of the new BPMV are not prefilled with brake fluid. * The automated bleed procedure is recommended when one of the following conditions exist: * Base brake system bleeding does not achieve the desired pedal height or feel * Extreme loss of brake fluid has occurred * Air ingestion is suspected in the secondary circuits of the brake modulator assembly The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run the pump in order to purge any air from the secondary circuits. These circuits are normally closed off, and are only opened during system initialization at vehicle start up and during ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped in these circuits to flow out away from the brake modulator assembly, which is then forced out at the brake corners by the pressure bleeder. Automated Bleed Procedure Caution: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Repair or replace components as needed. 4. Lower the vehicle. 5. Prepare the brake bleeding equipment and the vehicle for a pressure bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Hydraulic Brake System Bleeding). 6. Inspect the battery state of charge. Refer to Battery Inspection/Test (See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test). 7. Install a scan tool. 8. Turn the ignition ON, with the engine OFF. 9. With the scan tool, perform the following steps: 1. Select Diagnostics 2. Select the appropriate vehicle information 3. Select Chassis 4. Select Electronic Brake Control Module (EBCM) 5. Select Special Functions 6. Select Automated Bleed 10. With an assistant ready, raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Note: * Apply the brake pedal when instructed, using moderate effort. * Ensure the pedal remains applied until instructed to release by the scan tool. * Do not exceed the time period allowed by the scan tool for having the bleeder valves open. * The bleed sequence for each corner is as follows: - Left front - Right front - Right rear Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure 1. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 2. Disconnect the electrical connector from the park brake warning lamp switch. 3. Remove the park brake warning lamp switch screw (3). 4. Remove the park brake warning lamp switch (2) from the park brake pedal assembly (1). Installation Procedure Page 6613 Fuse Block - Underhood X5 (Battery Positive Cable) (without NVH) Fuse Block - Underhood X6 (Battery Positive Cable) Page 9034 Trim Panel: Service and Repair Center Pillar Lower Garnish Molding Replacement Center Pillar Lower Garnish Molding Replacement Page 9954 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors Yazaki Connectors Special Tools J-38125 Terminal Repair Kit Page 3895 Page 3551 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) (LAT or LE5 or LE9) Knock Sensor (KS) 1 (LZ4 or LZE or LY7) Page 5256 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the J-38125-5 - ultra torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Page 3063 Engine Control Module (ECM) X2 (LE5 or LE9) Page 9604 Page 1714 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the NEW stud into the bearing/hub assembly. Add enough washers (1) in order to draw the stud into the hub. 2. Install and tighten a wheel nut (2) until the head of the wheel stud is fully seated against the back of the bearing hub flange. 3. Remove the wheel nut (2) and the washers (1). 4. Install the brake rotor, and install the brake caliper and bracket as an assembly. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 6. Lower the vehicle. Page 1899 Engine Oil: Fluid Type Specifications ENGINE OIL TYPE Look for three things: 1. Your vehicle's engine requires oil meeting GM Standard GM6094M. 2. Oils meeting these requirements should also have the starburst symbol on the container. This symbol indicates that the oil has been certified by the American Petroleum Institute (API). You should look for this information on the oil container 3. All temperatures above -20°F (-29°C) SAE 5W-30 is best for your vehicle. These numbers on an oil container show its viscosity, or thickness. Do not use other viscosity oils such as SAE 10W-40, SAE 20W-50, or any other viscosity grade not recommended. NOTICE: Use only engine oil identified as meeting GM Standard GM6094M and showing the American Petroleum Institute Certified For Gasoline Engines starburst symbol. Failure to use the recommended oil can result in engine damage not covered by your warranty. GM Goodwrench oil meets all the requirements for your vehicle. If you are in an area of extreme cold, where the temperature falls below -20°F (-29°C), it is recommended that you use either an SAE 5W-30 synthetic oil or an SAE 0W-30 oil. Both will provide easier cold starting and better protection for your engine at extremely low temperatures. ENGINE OIL ADDITIVES / ENGINE OIL FLUSHES Do not add anything to your oil. The recommended oils with the starburst symbol that meet GM Standard GM6094M are all you will need for good performance and engine protection. Engine oil system flushes are not recommended and could cause engine damage not covered by the vehicle warranty. Page 2540 Camshaft Position (CMP) Sensor - Bank 2 Intake (LY7) Page 10093 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors Yazaki Connectors Special Tools J-38125 Terminal Repair Kit Page 3083 Page 4264 3. Install the transaxle brace (2) with bolt (3) seated in the brace. 4. Install the transaxle brace bolt (1) and tighten to 50 Nm (37 lb ft). 5. Tighten brace bolt (3) to 100 Nm (74 lb ft). 6. Install the transmission mount to bracket through bolt (1) and tighten to 90 Nm (66 lb ft). 7. Remove the jack stand. 8. Install the left tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 9. Lower the vehicle. Page 2911 Information Bus: Electrical Diagrams Data Communication Schematics Power, Ground, and High Speed Serial Data (without HP7) Power, Ground, and High Speed Serial Data (HP7) 4T45-E - Automatic Transmission Transmission Mode Indicator - A/T: Service and Repair 4T45-E - Automatic Transmission Automatic Transmission Control Indicator Replacement Page 4595 Control Module: Service and Repair Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover Replacement). 2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3). 5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring (8) to the side. Spring will be released with the removal of the control valve body assembly. 7. Remove the 2 control valve body bolts (4) M6 x 65. Page 4191 Shift Cable: Adjustments 6T70/6T75 - Automatic Transmission Range Selector Lever Cable Adjustment Warning The automatic transaxle range selector cable is made out of two cable sections. After initial connection never separate the two metal couplings from one another. Integrity of the connection of the two metal couplings will be lost if separation of the two metal couplings occurs. When servicing the transaxle remove the cable at the automatic transaxle range selector lever and at the automatic transaxle range selector cable bracket. If either section of the cable needs to be replaced, replace both of the cable sections. Loss of connection integrity of the two metal couplings can cause loss of transaxle shift control which could result in personal injury. Note: Adjust the automatic transmission range selector cable while the transmission and the gear selector are in the Park position only. Failure to do so may cause mis-adjustment. 1. Set the park brake and chock the wheels. 2. Verify the transmission range select lever is in the park position. 3. Verify the transmission manual shift lever is in the park position. 4. Release the range select cable adjuster clip (1). Page 3914 Fluid - A/T: Service Precautions Checking Hot Transmission Fluid through Drain Plug Hole Warning Warning The engine must be running when the transmission fluid fill plug is removed, or excessive fluid loss will occur. Transmission fluid may be hot. Since the actual fluid level is unknown, stand clear when removing the fill plug. Have a container ready to capture any lost fluid. Do not turn the engine off with the fill plug removed, as you can be injured by hot transmission fluid being expelled out of the oil fill opening. Rear Seat Shoulder Belt Retractor Replacement Seat Belt Retractor: Service and Repair Rear Seat Shoulder Belt Retractor Replacement Rear Seat Shoulder Belt Retractor Replacement Page 9369 3. Pull the finishing lace draw cord toward the sunroof opening. Remove the cord from the periphery of the opening. 4. Ensure that the finishing lace (2) is properly seated over the outer surface of the headliner (3). Page 2587 Air Cleaner Fresh Air Duct/Hose: Service and Repair Air Cleaner Inlet Duct Replacement Air Cleaner Inlet Duct Replacement Page 1919 Oil Pressure Sender: Diagrams Component Connector End Views Engine Oil Pressure (EOP) Sensor (LZ4 or LZE) Engine Oil Pressure (EOP) Switch (LAT or LE5 or LE9) Page 2513 Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 4. Remove the transaxle range switch lever nut and lever. 5. Remove the transaxle range switch bolts and remove the switch. Installation Procedure (Old Switch) 1. Make sure the transaxle manual shaft is in the Neutral position. 2. Align the flats on the transaxle shift shaft with the flats on the transaxle range switch and install the switch. 3. Loosely install the transaxle range switch bolts. Page 6926 1. Install the power steering pump flow control valve spring (2) into the power steering pump housing (1). 2. Install the power steering pump flow control valve (3) into the power steering pump housing (1). 3. Lubricate the power steering pump flow control valve fitting O-ring seal (4) with power steering fluid. 4. Install the power steering pump flow control valve fitting O-ring seal (4) onto the power steering pump flow control valve fitting (5). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the power steering pump flow control valve fitting (5) to the power steering pump housing (1). Tighten the fitting to 60 Nm (44 lb ft). Page 5434 Page 8785 Rear Door Exterior Handle: Service and Repair Rear Side Door Outside Handle Rod Adjustment Rear Side Door Outside Handle Rod Adjustment Removal Procedure 1. Remove the rear door trim panel. Refer to Rear Side Door Trim Panel Replacement (See: Rear Door Panel/Service and Repair/Rear Side Door Trim Panel Replacement). 2. Remove the rear door water deflector as needed. Refer to Rear Side Door Water Deflector Replacement (See: Rear Door Panel/Service and Repair/Rear Side Door Water Deflector Replacement). 3. Use a flat-head tool to open the clip from the threaded rod connecting the lock to the outside handle. 4. Adjust the travel of the handle by removing the threaded rod from the clip. Installation Procedure Page 945 1 - Seat Back Cover - Passenger 2 - Heated Seat Element - Passenger Back (KA1) 3 - Seat Back Cushion Pad - Passenger 4 - Seat Belt Switch - Passenger 5 - Seat Horizontal Motor - Passenger (1LZ) 6 - Seat Rear Vertical Motor - Passenger (1LZ) 7 - Heated Seat Control Module - Passenger (KA1) 8 - Seat Front Vertical Motor - Passenger (1LZ) 9 - Heated Seat Switch - Passenger (KA1) 10 - Seat Adjuster Switch - Passenger (1LZ) 11 - Inflatable Restraint Front Passenger Presence System (PPS) Module 12 - Seat Cushion - Passenger 13 - Heated Seat Element - Passenger Cushion (KA1) 14 - Seat Cover - Passenger Locations Parking Lamp Relay: Locations Electrical Center Identification Views Fuse Block - Rear Label Page 8221 Testing for a Short to Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure tests for a short to voltage in a circuit. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the Digital Multimeter (DMM) to the V (DC) position. 4. Connect the positive lead of the DMM to one end of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. Turn ON the ignition and operate all accessories. 7. If the voltage measured is greater than 1 V, there is a short to voltage in the circuit. Inducing Intermittent Fault Conditions Inducing Intermittent Fault Conditions Special Tools J 25070 Heat Gun Many intermittent open or shorted circuits are affected by harness/connector movement that is caused by vibration, engine torque, bumps/rough pavement, etc. In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: * Wiggling the harness * Disconnecting a connector and reconnecting * Stressing the mechanical connection of a connector * Pulling on the harness or wire in order to identify a separation/break inside the insulation * Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure). Another option is, with the component commanded ON and OFF by the scan tool, move related connectors and wiring and observe the component operation. With the engine running, move related connectors and wiring while monitoring engine operation. If harness or connector movement affects the data displayed, component/system operation, or engine operation, inspect and repair the harness/connections as necessary. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floor jacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents). Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. High Temperature Conditions If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. Page 1603 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off Vehicle (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Repair Instructions/Tire and Wheel Assembly Balancing - Off Vehicle). For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) 1400 K Street, N.W., Suite 900 Washington, DC 20005-2403 Telephone: 202-682-4800 E-mail: info@rma.org Website: www.rma.org Tire Rotation Tire Rotation Rotate the tire and wheel assemblies at frequent intervals to equalize wear. Refer to Maintenance Schedule (See: ). In addition to scheduled rotation, rotate the tire and wheel assembly whenever uneven tire wear is noticed. Radial tires tend to wear faster in the shoulder area, particularly in front positions. Radial tires in non-drive locations may develop an irregular wear pattern that may increase tire noise. This makes regular rotation especially necessary. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Page 7490 Blower Motor: Service and Repair Blower Motor Replacement Removal Procedure 1. Remove the right closeout panel. Refer to Instrument Panel Insulator Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement Right Side). 2. Remove the blower motor wire harness connector. Note: Cut through the case as straight as possible because the motor cup must be reused. In order to prevent damage to the component, do not cut any deeper than necessary to remove the motor cup. 3. Cut out the blower motor using a utility knife in the narrow groove of the lower case. 4. Remove the blower motor. Page 7005 10. Install the hexagon jam nut (2) to the inner tie rod assembly (1). 11. To assemble the outer tie rod assembly. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). Page 2823 Page 4950 18. Connect the RF brake pipe fitting (1) and tighten to 20 Nm (15 lb ft). Note: Ensure the electrical connector is correctly inserted into the EBCM prior to placing the locking lever into position. Failure to make a proper connection may cause communication problems with the module. 19. Connect the EBCM electrical connector. 20. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement (See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Radiator Surge Tank Replacement). 21. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding). 22. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration (See: Accessories and Optional Equipment/Pedal Positioning System/Pedal Positioning Sensor/Service and Repair/Brake Pedal Position Sensor Calibration). Page 1701 3. Reconnect the wheel speed senor electrical connector, if needed. 4. Install the wheel speed sensor electrical connector on the retaining bracket, if needed. 5. Install the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 6. Install the wheel drive shaft retaining nut and washer. Refer to Wheel Drive Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement). 7. Remove the support and lower the vehicle. Page 4263 7. Remove the transmission mount to transmission bolts (2). 8. Unclip the wiring harness retainer, then remove the transmission mount (1). Installation Procedure 1. Install the transmission mount (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission mount to transmission bolts (2) and tighten to 90 Nm (66 lb ft). Diagrams Amplifier: Diagrams Component Connector End Views Audio Amplifier X1 (UQA) Audio Amplifier X1 (UQ3) Page 9848 Rear Door Weatherstrip: Service and Repair Rear Door Upper Sealing Strip Replacement Rear Door Upper Sealing Strip Replacement Page 402 Air Bag Control Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module Replacement Page 3410 2. Push both sides of the quick connect fitting together in order to cause the retaining feature to snap into place. 3. Once installed, pull on both sides of the quick connect fitting in order to make sure the connection is secure. Page 2913 Page 3179 Heated Oxygen Sensor (HO2S) 2 (LAT or LE5 or LE9) Page 1889 7. Remove the oil level indicator tube bolt. 8. Remove the oil level indicator tube. 9. Remove the oil level indicator tube O-ring seals, if necessary. Installation Procedure 1. Install NEW oil level indicator tube O-ring seals, if necessary. 2. Install the oil level indicator tube. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the oil level indicator tube bolt and tighten to 10 Nm (89 lb in). 4. Raise and support the vehicle. Page 6451 Window Switch - Driver X1 Window Switch - Driver X2 Page 7211 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Service and Repair Rear Fender Liner: Service and Repair Rear Wheelhouse Panel Liner Replacement Page 9040 Rear Compartment Lid Pull Strap Replacement Rear Compartment Lid Pull Strap Replacement Page 5747 Fuse Block - Underhood X2 Page 8481 Audio Amplifier X3 (UQA) Page 5573 Seat Rear Vertical Motor - Driver (LTZ) Page 9362 6. Disconnect the rear sunroof drain hoses from the drain spigot. 7. Remove the push-pin fastener securing the rear sunroof water gutter to the roof. If equipped. 8. Remove the bolts that secure the sunroof module motor base to the roof. Page 2556 1. Lubricate the CKP sensor O-ring seal with clean engine oil. 2. Install the CKP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CKP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (1) to the CKP sensor. 5. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 6. Perform the crankshaft position system variation learn procedure. Refer to Crankshaft Position System Variation Learn (See: Testing and Inspection). 6T30/6T40/6T45 - Automatic Transmission Fluid - A/T: Testing and Inspection 6T30/6T40/6T45 - Automatic Transmission Transmission Fluid Level and Condition Check This procedure checks both the transmission fluid level, as well as the condition of the fluid itself. Caution: Use Dexron VI transmission fluid only. Failure to use the proper fluid may result in transmission internal damage. Note: Ensure the transmission has enough fluid in it to safely start the vehicle without damaging the transmission. With the vehicle off and the transmission fluid temperature at approximately 20-25°C (68-77°F) there must be at least enough fluid to drain out of the fluid level hole. This will ensure that there is enough fluid in the sump to fill the components once the vehicle is started. Non Dipstick Level Checking Procedure 1. Start the engine. 2. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in each range. Then move the shift lever back to PARK (P). 3. Allow the engine to idle 500-800 rpm for at least 3 minutes to allow any fluid foaming to dissipate and the fluid level to stabilize. Release the brake pedal. Note: If the TFT reading is not at the required temperature, allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached. If the fluid temperature is below the specified range, perform the following procedure to raise the fluid temperature to the specification. Drive the vehicle in second gear until the fluid temperature is at the specified temperature. 4. Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver Information Center or a scan tool. Caution: The transmission fluid level must be checked when the transmission fluid temperature (TFT) is at 85-95°C (185-203°F). If the TFT is not at this temperature, operate the vehicle or allow the fluid to cool as required. Setting the fluid level with a TFT outside this temperature will result in either an under or over-filled transmission. TFT 95°C under-filled, TFT 85°C over-filled. An under-filled transmission will cause premature component wear or damage. An over-filled transmission will cause fluid to discharge out the vent tube, fluid foaming, or pump cavitation. 5. Raise the vehicle on a hoist. The vehicle must be level, with the engine running and the shift lever in the PARK range. 6. While the vehicle is idling, remove the oil level set plug. Allow any fluid to drain. Oil Level Plug (1) * If the fluid is flowing as a steady stream, wait until the fluid begins to drip. * If no fluid comes out, add fluid until fluid drips out. Page 3329 Fuel Pressure: Testing and Inspection Fuel System Diagnosis Fuel System Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description The engine control module (ECM) enables the fuel pump relay when the ignition switch is turned ON. The ECM will disable the fuel pump relay within 2 seconds unless the ECM detects ignition reference pulses. The ECM continues to enable the fuel pump relay as long as ignition reference pulses are detected. The ECM disables the fuel pump relay within 2 seconds if ignition reference pulses cease to be detected and the ignition remains ON. The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal temperature of the fuel tank results in lower evaporative emissions. The fuel tank stores the fuel supply. An electric turbine style fuel pump attaches to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel feed pipe to the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump also supplies fuel to a venturi pump located on the bottom of the fuel pump module. The function of the venturi pump is to fill the fuel pump module reservoir. The fuel pressure regulator, a part of the fuel pump module, maintains the correct fuel pressure to the fuel injection system. The fuel pump module contains a reverse flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times. Reference Information Description and Operation Fuel System Description (See: Computers and Control Systems/Description and Operation/Fuel System Description) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Special Tools * CH 48027 - Digital Pressure Gauge * J 37287 - Fuel Line Shut-off Adapter * J 37287-FF - Fuel Line Shut-off Adapters, if equipped with an LE9 engine Circuit/System Verification Note: * Inspect the fuel system for damage or external leaks before proceeding. * Verify that adequate fuel is in the fuel tank before proceeding. * The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure. * Before proceeding with this test, review the User Manual CH 48027-5 for Safety Information Instructions. 1. Ignition ON, engine OFF, command the fuel pump relay ON with a scan tool. You should hear the fuel pump turn ON and OFF. Page 9917 Note: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern. * Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning) for replacement, setup, and programming. Testing for Short to Ground Testing for Short to Ground Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures test for a short to ground in a circuit. With a Digital Multimeter (DMM) 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the Ohms position. 4. Connect one lead of the DMM to one end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to one end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). * When the DMM displays voltage the short is in the wiring leading to the first connector or switch. * If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting with a Digital Multimeter Troubleshooting with a Digital Multimeter Danger: High voltage circuits should only be tested using a digital multimeter (DMM) and test leads with at least a CAT III rating, such as the J 39200-A Digital Multimeter. Failure to follow the procedures exactly as written may result in serious injury or death. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Digital Multimeter (DMM) Basic Requirements Service information is validated using digital multimeters that meet or exceed the following requirements. Using a multimeter that does not meet these basic requirements may give inaccurate readings which could lead to an incorrect diagnosis. Display and Settings 1. Four digits displayed 2. Voltage, amperage, resistance, frequency, diode test settings, and min-max function 3. Display positive and negative values Voltage 1. Have at least 10 M ohm input impedance Page 78 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Body Controls - BCM Cross Platform Functionality Body Control Module: All Technical Service Bulletins Body Controls - BCM Cross Platform Functionality INFORMATION Bulletin No.: 09-08-47-002 Date: November 17, 2009 Subject: Information on Body Control Module (BCM) Functionality Across Vehicle Lines Models: 2004-2010 Chevrolet Malibu 2008 Chevrolet Malibu Classic 2005-2010 Chevrolet Cobalt 2006-2010 Chevrolet HHR 2005-2009 Pontiac G6 2006-2009 Pontiac Solstice 2007-2009 Saturn AURA, SKY The purpose of this bulletin is to address the unique differences in Body Control Module (BCM) functionality of the affected vehicles. Many electrical functions on these vehicles do not directly involve the BCM, even though they may on other vehicles. The cooling fans, for example, are controlled by the engine control module (ECM) on the Malibu, but are controlled by the BCM on the Impala. The BCM is primarily a gateway between the high- and low-speed GMLAN serial data buses on the above listed vehicles. Functions That Do Not Involve the BCM The following list of features and functions are not controlled or dependent on the BCM: Important The BCM should NOT be replaced for conditions in these areas. - Cooling fans - Clock display - Radio display - Power mirrors - OnStar(R) - Rear wiper (on Malibu Maxx) - Warning lamps - Malfunction indicator lamp (MIL) - Driver seat belt reminder light and chime - Power windows Important The BCM also acts as a power distribution center and may provide a fused battery feed to the modules that actually do control the above functions. Do not assume a similar control module issue will apply to different vehicle lines. Refer to SI for the appropriate description and operation and diagnostic information. Disclaimer Page 7865 Air Bag Control Module: Diagrams Component Connector End Views Inflatable Restraint Front Passenger Presence System (PPS) Module Inflatable Restraint Sensing and Diagnostic Module (SDM) Page 8260 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 2092 7. Install the radiator surge tank pipe to the crossover pipe. 8. Install the radiator surge tank pipe bolts (2) and tighten to 10 Nm (89 lb in). 9. Install the radiator surge tank inlet hose to the inlet pipe. 10. Position the radiator surge tank inlet hose clamp (1) at the surge tank inlet pipe. 11. Install the power steering pump. Refer to Power Steering Pump Replacement (See: Steering and Suspension/Steering/Power Steering/Power Steering Pump/Service and Repair/Power Steering Pump Replacement). 12. Install the drive belt idler pulleys. Refer to Drive Belt Idler Pulley Replacement (). 13. Install the generator. Refer to Generator Replacement (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). 14. Install the intake manifold cover. Refer to Fuel Injector Sight Shield Replacement (). Page 10168 ^ When adding proper tire air pressure, it is important to remember fluctuations in outside air temperatures and tire temperatures effect tire air pressures. ^ After you have added the proper tire pressure, if the vehicle has a DIC (after the system has updated), check to see if DIC displays are the same readings as the tire pressure gauge used (adjust as necessary). ^ Only perform a TPM sensor re-learn after a tire rotation or system part replacements and use the Tech 2(R) to initiate the relearn whenever possible to avoid invalid sensor I.D. learns. Important: Always take outside temperature and tire temperature into consideration to properly set tire pressures. Foe example, on colder days (20°F/-7°C), if setting tire pressure when the vehicle has been indoors (60°F/16°C) or the tires are warm from being driven, it will be necessary to compensate for the low outside temperature by adding 21-27 kPa (3-4 psi) more then the placecard pressure. At some later time, when the vehicle has been parked outside for a while, the tires will cool off and the pressures will drop back into the placecard range. Important: Recently, nitrogen gas (for use in inflating tires) has become available to the general customer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. Tires inflated with nitrogen gas may exhibit less of a pressure change in response to outside temperature changes. Nitrogen gas inflation is compatible with GM TPM sensors. For additional information, refer to Corporate Service Bulletin 05-03-10-020C. Important: All Models (Except the Pontiac Vibe): Do not perform a TPM relearn at PDI, the system has already been set at the Assembly Plant. Do not perform a TPM relearn after adding air to the tires. The low tire light is similar to the low fuel indicator and adding something (fuel, air) to the vehicle makes that light turn back off again. Note that because of system behavior, some vehicles must be driven a short distance before the sensors recognize the increase in pressure and turns the light off again. Pontiac Vibe Only: Do not use the TPMS reset button to turn off the light. The system will update and light will turn off when all tire pressures have been adjusted followed by short distance drive. Important: All models (except the Pontiac Vibe): Each tire monitor sensor is learned to a specific vehicle corner. When performing a TPM relearn (only after a tire rotation or replacement of a TPM sensor or Module), always use the Tech2(R) to initiate the J 46079 relearned process. Tech 2(R) - initiated relearns lock out other vehicle TPM signals that may be broadcasting in the area. Only signals initiated by the J 46079 tool will be accepted. This method avoids storing false TPM I.D.s and will prevent customers from returning with dashes (--) displayed in tire pressure readouts and/or a flashing tire pressure monitor (TPM) light. Checking the four TPM I.D.s with the Tech 2(R) prior to and following relearn to verify they are the same can prevent invalid I.D. learns. Pontiac Vibe Only: Tire Monitor Sensors are not learned to a specific vehicle corner. Do not perform a TPM Reset after tire rotation. The TPMS Reset button must only be used during pre-delivery inspection by the dealer to initialize the system (after all tire pressures have been adjusted properly) or when a Tire Pressure Monitor System component is replaced. The J 46079 tool does not work on Vibe TPM sensors. A TPMS relearn on Vibe must be preformed with a Tech 2(R) to set the TPMS Module in learn mode. The TPMS sensor IDs are entered through the Tech 2(R). Refer to SI for further Vibe TPMS information. Labor Operation and Repair Order/Warranty System Claim Required Documentation Important: The ONLY time labor operation E0726 or E0722 should be used is to diagnose for a system issue. That should ONLY occur if, at key ON, without starting the engine, the Tire Pressure Monitor (TPM) blinks for one minute and then stays on solid with a Service Tire Monitor System message (on vehicles equipped with a DIC) If that occurs, a TPM system problem exists and the system will have set a DTC. If one of these operastions is used, the following Repair Order and Warranty System documentation are required: ^ Document the customer complaint on the Repair Order. ^ Document the TPMS DTC that has set on the Repair Order. ^ Enter the TPMS DTC in the Warranty System (WINS) in the Failure Code/DTC field on the claim submission (refer to the Claims Processing Manual, Section IV, Warranty claim Data, Page 6, Item G). If the above information is not documented on the Repair Order and Warranty System, the claim may be rejected. If the Warranty Parts Center (WPC) generates a request, this repair order documentation must be sent back. Locations Transmission Position Switch/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Left Rear of the Engine Compartment Components (ME7 or MN5) 1 - Park/Neutral Position (PNP) Switch Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) Page 10436 Page 7960 2. Disconnect connector C308 (1) from under the driver's seat cross-beam. The connector is accessible from the rear of the seat (2). Note Only use hand tools to remove the seat to the floor mounting bolts. If there are any problems with bolt removal, refer to Technical Service Bulletin 10-08-50-002. 3. Remove the driver's seat. Refer to Front Seat Replacement - Bucket in SI. Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Note The SIAB harness conduit is yellow on the Chevrolet Malibu. The SIAB harness conduit is black on the Pontiac G6. 5. Slide the conduit away and remove the tape (1). Caution Use caution when stripping insulation. Take care not to cut through the wire strands. 6. Slide the wire seals onto all four leads, back enough to enable removal of the insulation. Install the blue seals on the body harness and the white seals on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. 7. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals onto the bare wire using the J38125-7 crimp tool, Jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. Page 3671 Control Module: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 1532 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Page 6955 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Page 5684 Page 7359 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 3229 Variable Valve Timing Solenoid: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust (LY7) Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake (LY7) Page 4168 Shifter A/T: Diagrams Component Connector End Views Automatic Transmission Shift Lever Position Indicator Automatic Transmission Manual Shift Switch - Left (KB7) Steering Wheel Position Sensor Replacement Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Replacement Steering Wheel Position Sensor Replacement Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure Important: If replacing the steering wheel position sensor, the new sensor MUST come with a locating pin installed. If a locating pin is not installed, return and reorder a new steering wheel position sensor. Do not apply force to the steering wheel position sensor in a sideways direction. When reusing the steering wheel position sensor you must install a locating pin before removing it from the steering column. If the steering wheel position sensor loses its correct position it must be discarded. The locating pin diameter must be in the range of 1.0-2.0 mm. 1. Set the front wheels in the straight-ahead position and install anti-rotation pin J 42640 in the steering column lower access hole. 2. Disconnect the intermediate steering shaft from the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering and Suspension/Steering/Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 3. Disconnect any electrical connectors as needed. 4. Remove the steering wheel position sensor. Assembly Procedure Page 4167 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 7740 Control Module HVAC: Service and Repair HVAC - Manual HVAC Control Module Replacement Page 6462 Accessory AC/DC Power Control Module X1 (KV1) Locations Washer Fluid Level Switch: Locations Front of Vehicle/Engine Compartment Component Views Front and Right Rear of the Engine Compartment Components 1 - A/C Refrigerant Pressure Sensor 2 - Engine Cooling Fan - Right 3 - Engine Cooling Fan - Left 4 - Windshield Washer Fluid Pump 5 - Windshield Washer Fluid Level Switch 6 - Horn Assembly Page 2677 Page 18 Locations Transmission Temperature Sensor/Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (ME7 or MN5) 1 - Pressure Control (PC) Solenoid Valve 2 - 1-2, 4-3 Shift Solenoid (SS) Valve Assembly 3 Automatic Transmission Input Shaft Speed (ISS) Sensor 4 - 2-3 Shift Solenoid (SS) Valve Assembly 5 - Transmission Manual Shift Shaft Switch 6 - Automatic Transmission Output Shaft Speed (OSS) Sensor 7 - Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch 8 - Automatic Transmission Fluid Temperature (TFT) Sensor 9 - Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve Page 10508 2. Connect the MDI to the Data Link Connector (DLC) of the vehicle. Note Use the USB port to make the following MDI connection: 3. Connect the MDI to a PC or laptop that has been downloaded with the GDS application from TIS2WEB. Note At least one Diagnostic Package must be installed on the PC to perform diagnostics. If GDS was just installed, select: Add New Diagnostic Package and then select: a Diagnostic Package to download. 4. Click: On the GDS icon on the PC. 5. The Login Page will appear. 6. Select: A User. 7. The ID Screen will appear. 8. Select: The serial number of the MDI being used. 9. Select: Connect. 10. Verify that the system status is ready by observing for a flashing PC light icon on the MDI. 11. Select: Make, Model and Model Year, in order to build the vehicle. 12. Click: Upload VIN, to allow the VIN to be reported to the PC. 13. At: The Verification step, turn ON the ignition, with the engine OFF. 14. Select: Next Action. 15. The Home Page will appear. 16. Select: Next. 17. The Diagnostic Screen will appear. Note Due to vehicle build, software and RPO variations, GDS may ask for additional information in Step 18. 18. Select: Engine ID, if prompted. 19. Select: Module Diagnostics. 20. Select: ECM. 21. Select: ID Information. 22. The Diagnostics page will appear. Typical View of GDS Calibration History Screen Note GDS is capable of displaying up to 10 Calibration History events. 23. Select: Calibration History from the drop down menu in order to display the following items on the screen: - Calibration History Buffer - Number of Calibration History Events Stored - Calibration Part Number History - Calibration Verification Number History 24. Select: Screenshot. 25. Name and save the file in an appropriate folder. 26. Select : Print, and retain a copy of the screenshot with the repair order. Page 4713 20. Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14. 21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 22. Close the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent, fluid tank valve, then disconnect the J-29532 - Diaphragm Type Brake Pressure Bleeder, or equivalent, from the J-35589-A - Master Cylinder Bleeder Adapter. 23. Remove the J-35589-A - Master Cylinder Bleeder Adapter from the brake master cylinder reservoir. 24. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. 25. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. Note: If it is determined that air was induced into the system upstream of the ABS modulator prior to servicing, the Antilock Brake System Automated Bleed (See: Antilock Brake System Automated Bleed) must be performed. 26. If the brake pedal feels spongy, perform the following steps: 1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection (See: Hydraulic System/Testing and Inspection/Component Tests and General Diagnostics/Brake System External Leak Inspection). 2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to Antilock Brake System Automated Bleed (See: Antilock Brake System Automated Bleed). 27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Note: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes (See: Hydraulic System/Testing and Inspection/Symptom Related Diagnostic Procedures/Symptoms - Hydraulic Brakes). Page 4603 Page 3579 Page 533 Power Door Lock Switch: Diagrams Component Connector End Views Door Lock Switch - Driver Door Lock Switch - Passenger Page 4505 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual Valve Disassembled Views Disassembled Views Case and Associated Parts Electrical - Various Electrical Systems Malfunctions Body Control Module: All Technical Service Bulletins Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Page 8755 5. Move the striker to eliminate drag on the striker and door latch and to achieve proper door position within door opening. Start with up/down position, then position the striker to achieve proper alignment to the door opening. Set the in/out adjustment for proper door seal engagement ensuring that the door closing efforts are correct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Adjust the striker and add spacers as required. Tighten the screws to 20 Nm (15 lb ft). 7. Inspect the door for proper operation. 8. Close the door. Locations Transmission Control System Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Locations Steering Mounted Controls Transmitter: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 8396 Disclaimer Page 236 Page 941 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement Inflatable Restraint Side Impact Sensor Replacement Page 3077 1. Set the ECM (2) into the bottom of the bracket and push the ECM towards the battery until the ECM snaps into place and is secured by the retainers (1). 2. Connect the engine wiring harness electrical connectors (2) to the ECM. 3. Install the engine wiring harness clips (3) to the ECM bracket (4). Page 5478 Generator X1 (LE5 or LE9) Page 10298 Dimmer Switch: Diagrams Component Connector End Views I/P Dimmer Switch Page 7561 * Use TXL type wire Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 9294 Heated Seat Control Module - Driver X3 (KA1) Page 2325 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 9414 Seat Adjuster Switch - Driver (without LTZ and AG1) Page 8107 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement Inflatable Restraint Side Impact Sensor Replacement Page 241 Fuse Block - Rear Top View Locations Radiator Cooling Fan Motor Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 8804 Rear Door Panel: Service and Repair Rear Side Door Window Switch Bezel Replacement Rear Side Door Window Switch Bezel Replacement Page 5556 Radio X1 Page 3154 Note: Rotate the pigtail 90 degrees from vertical before securing the fastener. 1. Install the knock sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the knock sensor bolt and tighten to 25 Nm (18 lb ft). 3. Install the knock sensor electrical connector pigtail (6) clip to the oil level indicator tube bracket. 4. Connect the engine wiring harness electrical connector (1) to the knock sensor pigtail electrical connector (6). 5. Lower the vehicle. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). Page 2298 Body Control Module (BCM) X2 Page 4328 6. Remove the remaining control valve body bolts (9, 12, 16) and remove the control valve body assembly (18). 7. Remove the spacer plate support bolts (20) and remove the spacer plate support (21). Note: Checkballs may fall out of the channel plate assembly. Retain the checkballs with petroleum jelly. 8. Remove the spacer plate (90) with the spacer plate filter attached. 9. Remove and discard the spacer plate assembly (90). Disassembly/Assembly Procedure For step by step instructions on how to disassemble/assemble the control valve body, refer to Control Valve Body Disassemble (See: Service and Repair/Overhaul/4T45-E - Automatic Transmission/97. Control Valve Body Disassemble) and Control Valve Body Assemble (See: Service and Repair/Overhaul/4T45-E - Automatic Transmission/98. Control Valve Body Assemble). Installation Procedure Page 9925 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Page 8733 3. Connect electrical connector. 4. Install the front door trim panel. Refer to Front Side Door Trim Panel Replacement (See: Front Door Panel/Service and Repair/Front Side Door Trim Panel Replacement). Page 10340 Hazard Warning Switch: Service and Repair Hazard Warning Switch Replacement Page 5796 Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: Customer Interest Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 9788 1 - Seat Back Cover - Passenger 2 - Heated Seat Element - Passenger Back (KA1) 3 - Seat Back Cushion Pad - Passenger 4 - Seat Belt Switch - Passenger 5 - Seat Horizontal Motor - Passenger (1LZ) 6 - Seat Rear Vertical Motor - Passenger (1LZ) 7 - Heated Seat Control Module - Passenger (KA1) 8 - Seat Front Vertical Motor - Passenger (1LZ) 9 - Heated Seat Switch - Passenger (KA1) 10 - Seat Adjuster Switch - Passenger (1LZ) 11 - Inflatable Restraint Front Passenger Presence System (PPS) Module 12 - Seat Cushion - Passenger 13 - Heated Seat Element - Passenger Cushion (KA1) 14 - Seat Cover - Passenger Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Page 4829 4. Install the park brake cable to the caliper. 5. Remove the caps or plugs from the brake caliper opening and the brake hose. Note: DO NOT reuse the copper brake hose gaskets. 6. Install NEW copper brake hose gaskets to the brake hose-to-caliper bolt and to the brake hose. 7. Install the brake hose and the brake hose-to-caliper bolt to the brake caliper and tighten the bolt to 50 Nm (37 lb ft). 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding). 9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 9 and 10 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 13. Lower the vehicle. 14. Apply and release the park brake lever 4 times. Page 2666 Page 1825 2. Install the piston into its original bore using the EN-43966-1 - guides. 3. Lightly tap the top of the piston with a wooden hammer handle. 4. When installing the piston and the connecting rod, the stamped mark on the piston must point to the front of the engine. 5. Hold the EN-8037 - compressor firmly against the engine block until all the piston rings have entered the cylinder bore. 6. Install the connecting rod caps onto their original connecting rods. 7. Align the numbers placed on the connecting rod and the connecting rod cap during removal. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 8. Install the new connecting rod bolts and nuts. * On the first pass, tighten the nuts evenly to 25 Nm (18 lb ft). * On the final pass, use the EN-45059 - meter in order to tighten the nuts an additional 100 degrees. 9. Measure the connecting rod side clearance with a feeler gauge. The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in). 10. Install the cylinder head. Refer to Cylinder Head Replacement (See: Cylinder Head Assembly/Service and Repair/Cylinder Head Replacement). 11. Install the oil pan. Refer to Oil Pan Replacement (See: Engine Lubrication/Oil Pan/Service and Repair). Page 1448 Fuse Block - Underhood X1 Page 2019 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 1677 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Page 3872 4. Assemble the servo piston assembly into the servo cover. Lubricate the piston seals with transaxle fluid in order to aid in assembly. Installation Procedure Note: Hand start and tighten the servo cover bolts evenly to prevent damage to the servo cover bore. 1. Install the servo return spring into the transaxle case. 2. Install the servo cover and piston assembly over the servo return spring. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Hand start and install the servo cover bolts and tighten to 12 Nm (9 lb ft). 4. Install the oil pan. Refer to Oil Pan Replacement (See: Fluid Pan/Service and Repair). 5. Lower the vehicle. 6. Remove the AIR. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Symptom Related Diagnostic Procedures/4T45-E - Automatic Transmission/Transmission Fluid Level and Condition Check). 7. Add DEXRON(R) VI transaxle fluid or equivalent to the specified refill capacity. * The bottom pan removal capacity is approximately 6.5 L (6.9 qt). * The complete overhaul capacity is approximately 9 L (9.5 qt). * The dry capacity is approximately 12.2 L (12.9 qt). 8. Start the engine, warm up the transaxle, and check for leaks. 9. Inspect for proper fluid level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Symptom Related Diagnostic Procedures/4T45-E - Automatic Transmission/Transmission Fluid Level and Condition Check). Note: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 10. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and Operation/4T45-E - Automatic Transmission/Transmission Adaptive Functions). Page 10090 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Locations Wiper Motor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Engine Compartment Components (without LAT or HP7) Page 1996 10. On 2.2L engines, ensure the intake camshaft notch is in the 10 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at TDC, crankshaft key at 12 o'clock. 11. On 2.4L engines, ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at TDC, crankshaft key at 12 o'clock. Page 7945 Ensure that the appropriate wire colors match up (as noted in Step 4) when the connection is made between the seat airbag harness and body harness. 10. Slide all four terminals (2) into the appropriate connector body as shown above. Install the blue terminal position assurance (TPA) devices onto the connector ends. 11. Add NyoGel 760 Lubricant (dielectric lubricant), P/N 12377900 (in Canada, use P/N 10953529) (Saturn retailers, use P/N 12345579) to the terminals on both sides of the connections. 12. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the body harness up to the back of the connector. 13. Reinstall the conduit on the seat airbag harness. 14. Repeat the above procedure on the passenger seat. Reinstall Seats 1. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 2. Reconnect the seat to body harness connector and the seat airbag connector. Reroute Harness and Secure Connector Follow the procedure below to re-route and attach the harness connector to the body harness bundle: 1. The original seat airbag connector was attached with a clip to the bottom of the seat (2) as shown above. 2. Using two wire ties, secure the seat airbag connector to the seat wire bundle as shown. Ensure that there is enough slack for full range of motion of the seat. 3. Inspect the wires through the full range of motion of the seat again as in Step 2. Ensure that the wires have been secured in an orientation that allows full seat motion with adequate clearance to the connectors and sufficient slack in the wires. 4. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 5. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Page 3387 Fuel Injector 3 (LAT or LE5 or LE9) Fuel Injector 3 (LY7) Page 10033 Page 1757 5. Remove the exhaust camshaft (3). Note: Keep all of the roller followers and hydraulic adjusters in order so that they can be reinstalled in their respective locations. 6. Remove the camshaft roller followers. 7. Remove the hydraulic element lash adjusters. Installation Procedure 1. Install the hydraulic element lash adjusters into their bores in the cylinder head. 2. Lubricate the hydraulic lash adjusters Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). 3. Lubricate the valve tips with Adhesives, Fluids, Lubricants, and Sealers (See: Specifications/Adhesives, Fluids, Lubricants, and Sealers). Page 6436 Page 3810 Control Solenoid Valve Assembly (MH8) Body - Vehicle Glass Distortion Information Front Door Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 5994 Specifications Information Bus: Specifications Fastener Tightening Specifications Page 9654 The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors) * Delphi Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors) * FCI Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors) * Yazaki Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy Page 4258 3. Remove the left transmission mount to bracket bolts (1). 4. Remove the left transmission mount to body bolts (1). 5. Remove the transmission mount (2) from the vehicle. Installation Procedure Page 6747 For vehicles repaired under warranty, use the table. Disclaimer Page 3801 1 - Control Solenoid Valve Assembly (with Transmission Control Module) Page 7155 Note: When installing the rear spring, ensure that the spring is positioned so that bolt for the rear stabilizer shaft can be serviced and that the rear spring is properly seated in the upper and lower insulators. 2. Position the rear spring (1) on the lower control arm. 3. Using an adjustable jack stand, raise the lower control arm. 4. Install the lower control arm to knuckle bolt and nut. Refer to Rear Axle Lower Control Arm Replacement (See: Control Arm/Service and Repair/Rear Suspension/Rear Axle Lower Control Arm Replacement). 5. Remove the jack stands from the knuckle vehicle and the lower control arm. 6. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 7. Lower the vehicle. 8. Check the rear wheel alignment. Refer to Wheel Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement). Rear Spring Insulator Replacement Rear Spring Insulator Replacement To service the upper or lower insulators for the rear spring, refer to Coil Spring Replacement (See: Coil Spring Replacement). Service and Repair Fuel Level Sensor: Service and Repair Fuel Level Sensor Replacement Removal Procedure 1. Remove the fuel pump module assembly. Refer to Fuel Tank Fuel Pump Module Replacement (See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Pump/Service and Repair). 2. Disconnect the fuel level sensor electrical connector (1). 3. Disengage the locking tab (2) on the fuel level sensor by pushing inward. 4. Remove the fuel level sensor (1) from the alignment feature (2). Installation Procedure Page 598 Parking Brake Release Switch: Diagrams Component Connector End Views Park Brake Switch Page 2332 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 4259 1. Install the left transmission mount (2) to the vehicle. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transmission mount to body bolts (1) and tighten to 25 Nm (16 lb ft). 3. Install the left transmission mount to transmission bolts (1) and tighten to 50 Nm (37 lb ft). 4. Remove the floor jack supporting the engine. 5. Install the battery and tray. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair). Transmission Front Mount Replacement Transmission Front Mount Replacement Removal Procedure Page 6052 3. The lever should be in the full forward position. 4. Disconnect the connector from the component. Page 10293 Page 5707 X501 Inline Harness Connector End Views X501 Left Front Door Harness to Left Front Door Trim Pad Harness Page 7880 1 - Inflatable Restraint Front End Sensor - Left 2 - Ambient Air Temperature Sensor 3 - Inflatable Restraint Front End Sensor - Right Door Component Views Driver Door Components Page 5061 Page 3735 Input Speed Sensor Seal Replacement Page 6464 Accessory Power Outlet - I/P Accessory Power Outlet - 110V AC (KV1) Page 5928 Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the appropriate labor operation for the source of the water leak Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Diagrams Entertainment System Control Module: Diagrams Electrical Center Identification Views Fuse Holder - Digital Video Disc (DVD) Control Module (UJ5) Electrical - Various Electrical Concerns/False Messages Door Switch: Customer Interest Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Locations Transmission Mode Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (MH2) 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 7982 Note DO NOT replace the sensing and diagnostic module (SDM), side sensors or air bag modules. Note Both driver and passenger seats must be repaired when this concern occurs even if only one DTC code is set. The service kit contains sufficient components to repair both seat connectors. Connector Replacement Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above includes harness and connector clips, which are not required in this installation. Replace connectors on both driver and passenger seats, and then reposition the connectors following the steps below. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. Note Only use hand tools to remove the seat to floor mounting bolts. If there are any problems with bolt removal, refer to Corporate Bulletin Number 10-08-50-002. 2. Remove the driver's seat to floor mounting bolts. Loosen the seat from the front retainers and tilt it back to expose the underside of the seat. Refer to Front Seat Replacement - Bucket in SI. Page 767 1. Install the MAF/IAT sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1) and tighten to 2.5 Nm (22 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor (2). Page 216 Page 5809 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. 2008 Model Year Buick Enclave, GMC Acadia and Saturn OUTLOOK Vehicles Only Note The seat mounted side impact airbag connection to the body harness is located at the forward edge of the seat, below the plastic trim. The connectors are yellow. The body harness wires are exposed - running forward in the vehicle, down through the carpet cutout in the floor. Page 6620 Page 7904 Disclaimer Service Procedure Service Procedure Air Bag Connector Inspection 1. Move the driver's seat to the maximum forward position and raise the seat to its maximum height. 2. Using a flash light, locate the air bag and body wire harnesses. Note Vehicles that have new air bag connectors will have a tie strap securing the two (2) wires exiting the air bag connector to the main body wiring harness. In addition, the new air bag connectors will have an orange connector position assurance (CPA) clip that is tethered to the connector. Ensure both the orange CPA clip and tie strap are located. Air bag and body wire harnesses without the tie strap and/or CPA clip must have the air bag connectors replaced. 3. Determine if the new air bag connectors have been installed. - If the vehicle is equipped with the new air bag connectors, no further action is required. Refer to Warranty Transaction Information in this bulletin. - If the vehicle is NOT equipped with the new air bag connectors, replace the air bag connectors. Refer to Replace Wire Harness Connector in this bulletin. Replace Wire Harness Connector Tools Required - J-38125-7, Crimp Tool - J-38125-6, Crimp Tool Note The service kit shown above is early production and does not contain the correct color wire seals. Replace connectors on both driver and passenger seats, then reroute and attach the harnesses to the seat using the service kit. 1. Disable the SIR system. Refer to SIR Disabling and Enabling in SI. (Seat shown out-of-vehicles for illustration purposes) Page 4914 11. Remove the rear park brake cable from the caliper park brake lever. 12. Lower the vehicle. 13. Remove the plastic retainer clip (3) from the stud. 14. Remove the park brake cable and pass-through grommet (4) from the body and remove the cable from the vehicle. Installation Procedure Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Page 9720 16. If all circuits test normal, replace the heated seat module. Heated Seat Switch Circuit Test. 1. Ignition OFF, disconnect the harness connector at the appropriate heated seat switch. 2. Test for less than 5 Ohms between the ground circuit terminal 6 and ground. ‹› If greater than the specified range, test the ground circuit for an open/high resistance. 3. Ignition ON, verify that a test lamp illuminates between the B+ circuit terminal 5 and ground. ‹› If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance. 4. If all circuits test normal, test or replace the heated seat switch. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. * Driver or Passenger Seat Back Cushion Heater Replacement (See: Service and Repair/Driver or Passenger Seat Back Cushion Heater Replacement) * Driver or Passenger Seat Heater Switch Replacement (See: Seat Heater Switch/Service and Repair) * Front Seat Heater Control Module Replacement (See: Seat Heater Control Module/Service and Repair) * Driver Seat Cushion Heater Replacement (See: Service and Repair/Driver Seat Cushion Heater Replacement) * Passenger Seat Cushion Heater Replacement (See: Service and Repair/Passenger Seat Cushion Heater Replacement) Page 3951 Transmission Fluid Pump Cleaning and Inspection Transmission Fluid Pump Cleaning and Inspection Page 9779 Power Door Lock Switch: Service and Repair Door Lock Switch Replacement - Passenger Front Door Lock Switch Replacement - Passenger Front Electrical - Various Electrical Systems Malfunctions Body Control Module: All Technical Service Bulletins Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Locations Dimmer Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Service and Repair Condenser HVAC: Service and Repair Air Conditioning Condenser Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure Note: The desiccant is inside the condenser and is not serviced separately. The condenser must be replaced if new desiccant is required. 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 2. Remove the left and right headlamp assemblies. Refer to Headlamp Replacement (See: Lighting and Horns/Headlamp/Service and Repair/Removal and Replacement). 3. Loop a rope around each of the 2 upper tabs of the radiator and tie the rope around the upper tie bar. Page 1003 Tire Pressure Sensor: Service and Repair Tire Pressure Indicator Sensor Replacement Removal Procedure 1. Raise the vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire/wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Maintenance/Wheels and Tires/Tires/Service and Repair/Removal and Replacement). Note: If any of the following tire pressure sensor components are found to be damage, replace the damaged components. 4. Remove the tire pressure sensor indicator cap and deflate the tire. 5. Remove tire pressure sensor indicator nut (4). Note: When removing the tire pressure sensor, DO NOT re-use the seal, replace with new. 6. Remove the tire pressure sensor seal (3), the washer (2) and the tire pressure sensor (1). Installation Procedure Page 1407 Fuse Block - Underhood X2 Page 515 For vehicles repaired under warranty use the table above. Disclaimer Page 9345 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the sunroof water gutter screws and tighten to 2 Nm (18 lb in). 5. Install the sunroof module assembly. Refer Sunroof Frame Replacement (See: Sunroof / Moonroof Frame/Service and Repair). 6. Remove the masking tape from the roof panel. Page 10588 1 - Window Switch - Left Rear 2 - Window Switch - Right Rear 3 - Door Latch - Right Rear 4 Window Motor - Right Rear 5 - Window Motor - Left Rear 6 - Door Latch - Left Rear Page 1454 Fuse Block - Underhood X4 Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 10020 Page 185 Page 2843 visible evidence. Look for swollen and stiff sections of wire in the suspect circuits. * Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle. * Wiring that comes in contact with hot or exhaust components * Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required, in order to verify the customer concern. * Refer to Testing for Electrical Intermittents (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Electrical Intermittents) for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. * Refer to Scan Tool Snapshot Procedure (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Scan Tool Snapshot Procedure) for advanced intermittent diagnosis and Vehicle Data Recorder operation. Testing for Terminal Fretting Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface. To correct a fretting condition disconnect the suspect connector and add Nyogel lubricant 760G (dielectric grease) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion. Testing for Proper Terminal Contact It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the J 35616 when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Testing for Proper Terminal Contact in Bussed Electrical Centers (BEC) It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center (BEC). Use J-35616-35 to test for proper terminal contact. Failure to use J-35616-35 can result in improper diagnosis of the BEC. Follow the procedure below in order to test terminal contact: 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J-38125, test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact: 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. Page 6400 Seat Front Vertical Motor - Driver Seat Front Vertical Motor - Passenger Page 3524 Page 9531 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 5638 Air Temperature Sensor - Upper (C68) Ambient Air Temperature Sensor Page 9439 6. Install the lower seat back frame bolts and caps, and tighten the bolts to 35 Nm (26 lb ft). 7. Install the rear seat belt buckle nuts (2,3) and tighten 45 Nm (33 lb ft). 8. Install the outer rear seat belt lower anchors bolts (1,4) and tighten 45 Nm (33 lb ft). 9. Install the rear seat cushion. Refer to Rear Seat Cushion Replacement (See: Seat Cushion/Service and Repair/Rear Seat Cushion Replacement). Page 5411 Digital Radio Receiver (U2K) Page 5320 Page 10027 Service and Repair Parking Brake Warning Switch: Service and Repair Parking Brake Indicator Switch Replacement Removal Procedure 1. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 2. Disconnect the electrical connector from the park brake warning lamp switch. 3. Remove the park brake warning lamp switch screw (3). 4. Remove the park brake warning lamp switch (2) from the park brake pedal assembly (1). Installation Procedure Page 9644 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Page 3694 Fluid Pressure Sensor/Switch: Diagrams Component Connector End Views Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch (ME7 or MN5) Campaign - Service Air Bag Message, Replace Connectors Technical Service Bulletin # 11034 Date: 110314 Campaign - Service Air Bag Message, Replace Connectors CUSTOMER SATISFACTION Bulletin No.: 11034 Date: March 14, 2011 Subject: 11034 - Service Air Bag Message - Replace Connectors Models: 2010 Chevrolet Malibu 2010 Pontiac G6 Some, but not all, of the vehicles involved in this Program were also involved in Customer Satisfaction Program (CSP) 10085. These vehicles are to be inspected to determine if the repair for CSP 10085 included the replacement of the two connectors. If the connectors were replaced, no further action is required on these vehicles. If they were not replaced, dealers are to install the new connectors. Condition Certain 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may have a condition in which wear could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact airbag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG system warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG system DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Some of these vehicles were previously repaired under Customer Satisfaction Program 10085. These vehicles had the wire harness secured, and in some cases, rerouted. They did not require the installation of the two connectors. However, there have been reports of the SERVICE AIR BAG message illuminating in the Driver Information Center after the repair, due to movement of the connector between the body main wiring harness and the front driver and passenger side impact air bag. With this Customer Satisfaction Program, dealers will install the two new connectors. Correction Dealers are to inspect and, if necessary, replace the front seat-mounted side impact air bag connectors. Vehicles Involved Involved are certain 2010 model year Chevrolet Malibu and Pontiac G6 vehicles. Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty Management system. Not all vehicles may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order. Page 587 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 4778 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Page 4216 2. Install the transmission side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions See: Description and Operation. Page 2856 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 10754 Wiper Switch: Service and Repair Windshield Wiper and Washer Switch Replacement Page 4096 85 - Transaxle Oil Filter Assembly 86 - Oil Level Control Valve 87 - Transaxle Bottom Pan Gasket 88 - Transaxle Oil Pan 89 - Chip Collector Magnet 120 - Chip Collector Magnet (Some Models) 126 - Side Cover Stud 127 - Transmission Wiring Harness Assembly (Some Models) 128 - Electrical Connector Retaining Bracket (Some Models) Case and Associated Parts - L4 Hybrid 1 - Side Cover (Structural) 2 - Axle Oil Seal 3 - Side Cover Bolt 4 - Side Cover Stud 5 - Side Cover Gasket 6 - Side Cover Oil Level Control Gasket 7 - Thrust Washer (Side Cover to Driven Sprocket) 8 - Oil Pump Bolt 9 - Oil Pump Bolt 10 - Transaxle Oil Pump Assembly 11 - Transaxle Wiring Assembly 12 - TFP Manual Valve Position Switch Assembly Bolt 13 - TFP Manual Valve Position Switch Assembly 15 - Wiring Harness Bracket Bolt/Input Speed Sensor Bolt 51 - Transaxle Case 52 - Vent Cap 55 - Torque Converter Assembly 61 - Output Speed Sensor Stud 62 - Output Shaft Speed Sensor 63 - O-Ring Seal (Output Speed Sensor) Page 4256 1. Install the transaxle brace (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the transaxle brace bolt (1) and tighten to 50 Nm (37 lb ft). 3. Install the transaxle brace bolt (3) and tighten to 100 Nm (74 lb ft). 4. Lower the vehicle. Transmission Mount Bracket Replacement - Rear Transmission Mount Bracket Replacement - Rear Removal Procedure 1. Remove the rear transmission mount. Refer to Transmission Rear Mount Replacement (See: Transmission Rear Mount Replacement). Page 2099 Page 9492 Page 1134 1. Relieve the fuel system pressure, if required. Perform the following steps: Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Wrap a shop towel around the fuel rail service port. 2. Place the hose on the CH-48027-2 adapter (2) into an approved gasoline container. 3. Open the valve on the CH-48027-2 - adapter (2) in order to bleed any fuel from the fuel rail. 4. Close the valve on the CH-48027-2 - adapter (2). 5. Remove the hose on the CH-48027-2 - adapter (2) from the approved gasoline container. 6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container. Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: * The fuel pipe connections * The hose connections * The areas surrounding the connections 2. Disconnect the CH-48027-1 - gauge (1) from the CH-48027-2 - adapter (2). 3. Disconnect the CH-48027-2 - adapter (2) from the CH-48027-2 - adapter (3). 4. Disconnect the CH-48027-2 adapter (3) from the fuel rail service port. 5. Install the fuel rail service port cap. 6. Install the engine cover, if required. 7. Tighten the fuel fill cap. Page 10350 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 4777 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Page 528 Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Replacement Brake Pedal Position Sensor Replacement Page 1586 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Page 337 Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Page 2820 Page 7269 up, allowing tire air pressure to increase above the threshold causing the light to go off. Properly adjusting all tire air pressures to the recommended levels will correct this (Refer to the Tire and Loading Information Label on the driver side door). - More detailed information can be found in the Owner Manual. - Service is not covered under warranty - this maintenance is the responsibility of the owner. - Give the customer a copy of the "GM Customer TPMS Information". For more detailed information, refer to Corporate Bulletin Number 07-03-16-004C and TPMS Training Course 13044.12T2. Tire Pressure Light At key on, without starting the vehicle: Steady Solid Glowing TPM Indicator If the TPM indicator appears as a steady glowing yellow lamp (as above), the system is functioning properly and you should add air to the tires to correct this condition. Blinking TPM Indicator If the TPM indicator appears as a BLINKING yellow lamp for one minute and then stays on solid, diagnostic service is needed. The Effect of Outside Temperature on Tire Pressures Important: As a rule of thumb, tire pressure will change about 7kPa (1 psi) for every 6°C (10°F) decrease in temperature - Tire pressure will drop when it gets colder outside, and rise when it gets warmer. Under certain situations such as extreme outside temperature changes, the system may bring on a solid light with a check tire pressure message. This should be considered normal and the system is working properly. The light will turn off upon adding the proper amount of air to the tires (refer to the Tire & Loading Information label in the driver's door opening). When properly adjusting tire air pressure, the following steps are important to help optimize the system and prolong bringing a tire pressure light on: ^ Use an accurate, high quality tire pressure gauge. ^ Never set the tire pressure below the specified placard value regardless of tire temperature or ambient temperature. ^ Tire pressure should be set to the specified placard pressure at the lowest seasonal temperature the vehicle will encounter during operation. Page 1270 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the power steering hose bracket and nut (1, 2). Tighten the nut to 5 Nm (45 lb in). 4. Compress the power steering reservoir inlet hose clamp (1) and connect the power steering reservoir inlet hose to the power steering fluid reservoir. 5. Clean any excess power steering fluid from the vehicle and remove the drain pans. 6. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Intake Manifold Cover Replacement). 7. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Steering and Suspension/Steering/Power Steering/Power Steering Bleeding/Service and Repair). Page 6423 Steering Wheel Control Switch - Right (UK3) Page 9485 Page 7606 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 6280 Page 3591 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) (LAT or LE5 or LE9) Knock Sensor (KS) 1 (LZ4 or LZE or LY7) Page 10184 Page 4590 Page 542 Power Mirror Switch: Service and Repair Power Mirror Switch Replacement Page 5946 Ensure that the appropriate wire colors match up (as noted in Step 4) when the connection is made between the seat airbag harness and body harness. 10. Slide all four terminals (2) into the appropriate connector body as shown above. Install the blue terminal position assurance (TPA) devices onto the connector ends. 11. Add NyoGel 760 Lubricant (dielectric lubricant), P/N 12377900 (in Canada, use P/N 10953529) (Saturn retailers, use P/N 12345579) to the terminals on both sides of the connections. 12. Wrap Woven Polyester Electrical Tape (PET) (preferred) or equivalent anti-abrasion tape or electrical tape around the two exposed wires on the body harness up to the back of the connector. 13. Reinstall the conduit on the seat airbag harness. 14. Repeat the above procedure on the passenger seat. Reinstall Seats 1. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 2. Reconnect the seat to body harness connector and the seat airbag connector. Reroute Harness and Secure Connector Follow the procedure below to re-route and attach the harness connector to the body harness bundle: 1. The original seat airbag connector was attached with a clip to the bottom of the seat (2) as shown above. 2. Using two wire ties, secure the seat airbag connector to the seat wire bundle as shown. Ensure that there is enough slack for full range of motion of the seat. 3. Inspect the wires through the full range of motion of the seat again as in Step 2. Ensure that the wires have been secured in an orientation that allows full seat motion with adequate clearance to the connectors and sufficient slack in the wires. 4. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 5. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Fuse Block - Underhood Relay Box: Locations Fuse Block - Underhood Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 7165 Second Design - Black Painted (DO NOT Lube) Hydraulic Assist Power Steering First Design - Bare Steel Tube (Lube OK) Second Design - Black Painted (DO NOT Lube) In the unlikely event that the source of the noise is identified as a second design shaft with black painted tube, it must be replaced. Correction 1 (Only for First Design - DO NOT USE FOR 2ND DESIGN) Lubricate the intermediate shaft with steering column shaft lubrication kit, P/N 26098237. 1. From inside the vehicle, remove the instrument panel insulator panel - left side panel to gain access to the intermediate shaft. 2. Remove the intermediate shaft to steering column attachment bolt. 3. Remove the intermediate shaft from the steering column. 4. Extend the intermediate shaft all the way. Using the intermediate shaft grease kit, P/N 26098237, inject the grease into the gap between the inner shaft and the outer shaft as you are collapsing the shaft. This will draw the grease into the shaft. 5. Cycle the shaft up and down several times to distribute the grease. Important Remove original thread locker material from the bolt and apply Loctite(R) 242 (or equivalent) to the threads of the bolt and reinstall intermediate shaft bolt. 6. Install the intermediate shaft to the column. Tighten - For electronic power steering, tighten the bolt to 49 Nm (36 lb ft). - For hydraulic power steering, tighten the bolt to 62 Nm (46 lb ft). Page 5340 Fuse Block - Underhood X4 Page 6773 3. Disconnect the seat to body harness connector (1). Disconnect the seat airbag connector (2). Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing into the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Slide the conduit away on the seat airbag harness and remove just enough tape on the body harness to access the wires to install the terminals and seals. Note Use caution when stripping insulation. Take care not to cut through the wire strands. 5. Slide the wire seals onto all four leads back enough to enable removal of the insulation. Install the blue seals (1) on the body harness and the white seals (2) on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Testing and Inspection Brake Caliper: Testing and Inspection Brake Caliper Inspection Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions are present, the brake caliper requires replacement. 2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in the caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement. 3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement. 4. Inspect for smooth and complete travel of the caliper pistons into the caliper bores: The movement of the caliper pistons into the caliper bores should be smooth and even. If the caliper piston is frozen or difficult to bottom, the caliper requires overhaul or replacement. * For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the piston in the bore. * For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the brake pad or block of wood, slowly bottom the pistons evenly into the bores. Page 8470 1 - Brake Pedal Position (BPP) Sensor 2 - Accelerator Pedal Position (APP) Sensor 3 - Accelerator Pedal 4 - Brake Pedal Page 3861 2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid valve spring (7) into position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Install all bolts before tightening, then tighten in specified sequence. 4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x 55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6 x 42. 8. Install the 2 control valve body bolts (4) M6 x 65 and tighten to 12 Nm (106 lb in). 9. Connect the input speed sensor electrical connector (1). 10. Connect the output speed sensor electrical connector (2). 11. Connect the shift position switch electrical connector (3). 12. Install the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/6T70/6T75 - Page 5627 Windshield Wiper Motor Windshield Wiper/Washer Switch Page 7321 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Page 6245 Digital Video Disc (DVD) Control Module X5 (SPO Accessory) (UJ5) Service and Repair Parking Brake Cable: Service and Repair Parking Brake Rear Cable Replacement Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Removal Procedure 1. Ensure that the park brake pedal is in the fully released position. 2. Remove the front floor console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 3. Remove the rear carpet. Refer to Rear Floor Panel Carpet Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Removal and Replacement/Rear Floor Panel Carpet Replacement). 4. Remove the right rear park brake cable (1) or the left rear park brake cable (2) from the console park brake bracket (5) and the front park brake cable equalizer (6). 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). Page 3682 Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover Replacement). 13. If a NEW TCM has been installed into the vehicle, the NEW module needs to be reprogrammed. Refer to Service Programming System (SPS) ( See: Testing and Inspection/Programming and Relearning/Service Programming System (SPS)). Note: The Service Fast Learn Adapts procedure must be performed when one of the following repairs have been made to the vehicle. Failure to perform the procedure after one of the following repairs may result in poor transmission performance, as well as transmission DTCs being set: * Transmission internal service/overhaul * Valve body repair or replacement * Control solenoid valve assembly replacement * TCM software/calibration update * Any service in response to a shift quality concern 14. Perform the Service Fast Learn Adapts. Refer to Service Fast Learn Adapts (See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning/6T70/6T75 Automatic Transmission). Page 6640 3. Disconnect the seat to body harness connector (1). Disconnect the seat airbag connector (2). Note Note the wire colors on the seat airbag harness and body harness. Ensure that the wire colors are matched when installing into the new connector. 4. Cut both wires from the body harness connector and seat airbag harness connector as close to the connector housing (1) as possible to minimize wire length loss. Slide the conduit away on the seat airbag harness and remove just enough tape on the body harness to access the wires to install the terminals and seals. Note Use caution when stripping insulation. Take care not to cut through the wire strands. 5. Slide the wire seals onto all four leads back enough to enable removal of the insulation. Install the blue seals (1) on the body harness and the white seals (2) on the seat airbag harness. Strip the insulation off all four leads 5 mm (3/16 in). Align the seals with the wire insulation. Page 4101 14 - Driven Sprocket 15 - 1-2-3-4 Clutch Assembly 16 - Low and Reverse Clutch Assembly 17 - 2-6 Clutch Assembly 18 - 3-5 Reverse Clutch Assembly 19 - 4-5-6 Clutch Assembly 20 - A/Trans Input Speed Sensor Assembly 21 - Reaction Sun Gear Assembly Component Location Component Location Component Locations 1 - Manual Shift Detent Lever Assembly (w/Shaft Position Switch) 2 - Trans Fluid Level Indicator 3 Reaction Carrier Assembly 4 - Output Speed Sensor 5 - Input Carrier Assembly 6 - Output Carrier Assembly 7 - Front Differential Transfer Drive Gear 8 - Front Differential Transfer Drive Gear Support Assembly Page 6474 Automatic Transmission Auxiliary Fluid Pump (HP7 with ME7) Page 6527 X402 Inline Harness Connector End Views X402 Rear Lamp Harness to Right Tail Lamp Harness (without LTZ) X403 Inline Harness Connector End Views X403 Body Harness to Rear Wheel Speed Sensor Harness Page 470 Page 1023 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (ME7 or MN5) Page 3564 Camshaft Position Sensor: Diagrams Component Connector End Views Camshaft Position (CMP) Sensor - Bank 1 Exhaust (LY7) Camshaft Position (CMP) Sensor - Bank 1 Intake (LY7) 4T45-E - Automatic Transmission Valve Body: Service and Repair 4T45-E - Automatic Transmission Control Valve Body Cover Replacement Control Valve Body Cover Replacement Removal Procedure 1. Remove the battery tray assembly. Refer to Battery Tray Replacement (See: Starting and Charging/Battery/Battery Tray/Service and Repair). 2. Disconnect the shift cable from the park neutral position (PNP) switch. 3. Remove the shift cable bracket. Page 727 For vehicles repaired under warranty use the table above. Disclaimer Page 3256 Page 1511 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Testing and Inspection). Page 5350 Fuse Block - Rear X3 Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Switch Replacement Removal Procedure 1. Remove the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). 2. Disconnect the engine wiring harness electrical connector (2) from the oil pressure switch. 3. Remove the engine oil pressure switch. Installation Procedure Page 2505 Throttle Position Sensor: Diagrams Component Connector End Views Accelerator Pedal Position (APP) Sensor Page 5295 * Use TXL type wire Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 7031 7. Wipe off any excessive grease on the intermediate shaft to avoid damage from drips on the carpet. 8. Install the instrument panel insulator panel - left side. 9. Verify that the noise is no longer present. Condition 2 There may be interference between the clamp and the steering gear input shaft. The clamp is beveled and if forced down on the input shaft too hard, it may cause a loose fit with the intermediate shaft to input shaft joint. Correction 2 To correct this condition, perform the following steps: 1. Remove the intermediate shaft pinch bolt at the steering gear end. 2. Install a new bolt, GM P/N 07845238, but do not tighten the bolt at this time. 3. Pry the clamp up using a pry bar to position the bolt into the upper part of the groove as shown above. This will position the clamp off the bevel. 4. While keeping the clamp in the upper position, tighten the bolt. Tighten Tighten the bolt to 49 Nm (36 lb ft). 5. Verify that the clunk noise is no longer present. Condition 3 Important This condition ONLY applies to 2004-2007 Chevrolet Malibu/Maxx and 2005-2007 Pontiac G6. Some customers may comment on a knocking or rattling type noise from the front of the vehicle when driven at low speeds and over bumps. The noise only occurs when the steering wheel is in the straight ahead position and sounds like the noise is in the left suspension of the vehicle or directly in front of the driver. Correction 3 1. Ensure the noise is not caused by Condition # 1. 2. Determine the source of the noise. Install the chassis ears at the following locations: - sway bar link - one side at a time - upper strut mount - one side at a time - steering gear near the pinion area - base of the steering column housing - radiator surge tank 3. If the noise is coming from the upper strut mount or sway bar link, replace as necessary and retest. 4. For 2004-2006 Chevrolet and Pontiac model year vehicles, the noise may be coming from the radiator surge tank area. (The 2007 model year vehicles use a different style radiator surge tank - refer to Step 9.) 5. If the noise is coming from the radiator surge tank, release the two retaining tabs holding the radiator surge tank and reposition the tank away from the attaching bracket and isolate with closed cell foam. 6. Cut three pieces of closed cell foam, P/N P46515 (or equivalent), into 25 mm (1 in) by 102 mm (4 in) pieces. 7. Cut two pieces of closed cell foam into 25 mm (1 in) by 6 mm (1/4 in) pieces. Locations Main Relay (Computer/Fuel System): Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 9883 Page 1200 1. Install a NEW air filter assembly. 2. Close the air cleaner cover. 3. Engage the air cleaner cover latches (1). 4. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor. 5. Install the air cleaner outlet duct to the air cleaner assembly. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Tighten the air cleaner outlet duct clamp at the air cleaner assembly to 4 Nm (35 lb in). Page 4041 2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid valve spring (7) into position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Install all bolts before tightening, then tighten in specified sequence. 4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x 55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6 x 42. 8. Install the 2 control valve body bolts (4) M6 x 65 and tighten to 12 Nm (106 lb in). 9. Connect the input speed sensor electrical connector (1). 10. Connect the output speed sensor electrical connector (2). 11. Connect the shift position switch electrical connector (3). 12. Install the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/6T70/6T75 - Page 4632 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Page 1962 14. Use the EN-36017 - seal remover (1) to remove the valve seal. Installation Procedure 1. Using the EN-36017 - seal remover (1) install the NEW valve seal. Fully seat the seal onto the valve guide. Page 3128 Crankshaft Position Sensor: Testing and Inspection Crankshaft Position System Variation Learn Note: The crankshaft position (CKP) system variation learn procedure is required when the following service procedures have been performed, regardless of whether DTC P0315 is set: * Engine replacement * Engine control module (ECM) replacement * Crankshaft damper replacement * Crankshaft replacement * CKP sensor replacement * Any engine repairs which disturb the crankshaft to CKP sensor relationship Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the CKP system variation learn procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: * CKP sensor activity-If there is a CKP sensor condition, refer to the applicable DTC that set. * Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC that set. * Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 1. Install a scan tool. 2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 3. With a scan tool, select the CKP system variation learn procedure and perform the following: 1. Observe the fuel cut-off for the applicable engine. 2. Block the drive wheels. 3. Set the parking brake. 4. Place the vehicle's transmission in Park or Neutral. 5. Turn the air conditioning (A/C) OFF. 6. Cycle the ignition from OFF to ON. 7. Apply and hold the brake pedal for the duration of the procedure. 8. Start and idle the engine. 9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle immediately if the value is exceeded. Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 10. Release the throttle when fuel cut-off occurs. 4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 (See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/P Code Charts/P0315). If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List - Vehicle (See: Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) for the applicable DTC that set. 5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. Page 9730 Seat Heater Control Module: Diagrams Component Connector End Views Heated Seat Control Module - Driver X1 (KA1) Heated Seat Control Module - Driver X2 (KA1) Page 7984 6. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals on to the bare wire using the J38125-7 crimp tool, jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 7. Position the wire seal to the terminal and crimp the seal and insulation using the J-38125-6 crimp tool, jaw 1 (1). The completed terminal and seal should appear as shown above (body harness connector shown). Note Avoid getting solder on the terminal end or overheating the terminal. Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. 8. Solder all four terminals at the wire crimp. 9. Slide the two body harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Page 10717 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Page 764 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 8751 Front Door Panel: Service and Repair Front Side Door Trim Panel Replacement Front Side Door Trim Panel Replacement Page 5173 Page 1798 Note: Use 4 old cylinder head bolts for the attaching bolts. 3. Insert the 4 attachment bolts into the legs of the EN 45680-881 fixture (1). Do not apply downward pressure to the cylinder bore sleeve (2). Tighten the 4 attachment bolts to 15 Nm (11 lb ft). 4. Align the bottom of the cylinder bore sleeve (1) with the cylinder bore of the block (2). Page 1328 1. Install the NEW oil filter to the cap. 2. Install the oil filter cap and filter. Caution: Over torquing the oil filter cap may cause damage to the oil filter cap resulting in an oil leak. Note: DO NOT use an open end wrench on the hex on top of the oil filter cap. 3. use an oil filter wrench on the outside diameter of the oil filter cap. Tighten the oil filter cap until fully seated. DO NOT exceed 25 Nm (18 lb ft). 4. Fill the engine with oil. Refer to Fluid and Lubricant Recommendations (See: ). Page 4039 Control Module: Service and Repair Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/6T70/6T75 Automatic Transmission/Control Valve Body Cover Replacement). 2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3). 5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring (8) to the side. Spring will be released with the removal of the control valve body assembly. 7. Remove the 2 control valve body bolts (4) M6 x 65. Page 8483 Page 2460 1. Install the MAF/IAT sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1) and tighten to 2.5 Nm (22 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor (2). Page 3818 Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover Replacement). 13. If a NEW TCM has been installed into the vehicle, the NEW module needs to be reprogrammed. Refer to Service Programming System (SPS) ( See: Testing and Inspection/Programming and Relearning/Service Programming System (SPS)). Note: The Service Fast Learn Adapts procedure must be performed when one of the following repairs have been made to the vehicle. Failure to perform the procedure after one of the following repairs may result in poor transmission performance, as well as transmission DTCs being set: * Transmission internal service/overhaul * Valve body repair or replacement * Control solenoid valve assembly replacement * TCM software/calibration update * Any service in response to a shift quality concern 14. Perform the Service Fast Learn Adapts. Refer to Service Fast Learn Adapts (See: Automatic Transmission/Transaxle/Testing and Inspection/Programming and Relearning/6T70/6T75 - Automatic Transmission). Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Page 2218 5. Remove the lower right HO2S (2) using the J 39194-B. 6. Remove the left (front) catalytic converter to right (rear) catalytic converter nuts (3). 7. Remove the right (rear) catalytic converter bolt (5) and nuts (1) at the exhaust manifold. 8. Remove the right catalytic converter (2). 9. Remove and discard the gasket (6). 10. Inspect the catalytic converter-to-exhaust manifold flange. * Service Limit: 0.7 mm (0.028 in) max. * Standard: 0.7 mm (0.028 in) max. Installation Procedure Page 8165 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Page 6158 Fuse Block - Underhood Top View (LAT) Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Malfunction Indicator Lamp (MIL) Diagnosis Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Circuit/System Description Ignition voltage is supplied to the malfunction indicator lamp (MIL). The engine control module (ECM) turns the MIL ON by grounding the MIL control circuit. For example, a failure condition exists if the ECM detects low voltage when the MIL is commanded OFF, or high voltage when the MIL is commanded ON. Reference Information Schematic Reference * Instrument Cluster Schematics (See: Diagrams/Electrical Diagrams/Instrument Panel, Gauges and Warning Indicators/System Diagram/Instrument Cluster Schematics) * Engine Controls Schematics (See: Diagrams/Electrical Diagrams/Powertrain Management/System Diagram) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Scan Tool Reference Control Module References (See: Testing and Inspection/Programming and Relearning) for scan tool information Circuit/System Verification 1. Ignition ON, command the MIL ON and OFF with a scan tool. The MIL should turn ON and OFF as commanded. 2. Command the MIL ON and OFF with a scan tool while observing the following control circuit status parameters: * MIL Ckt. Short Gnd Test Status * MIL Ckt. Open Test Status * MIL Ckt. Short Volts Test Status Each parameter should change from OK and Not Run or from Not Run and OK. 3. Operate the vehicle within the Conditions for Running the DTC to verify that the DTC does not reset. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data. Circuit/System Testing 1. Ignition ON, verify that the instrument panel cluster (IPC) warning indicators are illuminated. ‹› If the IPC warning indicators are not illuminated, test the ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the ignition circuit fuse is open, replace the IPC. 2. Ignition OFF, disconnect ECM X1 harness connector. Ignition ON, the MIL should not illuminate. Page 1429 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Luggage Compartment/Rear of Vehicle Component Views Left Side of the Luggage Compartment Components Page 5109 Page 4452 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 5249 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 5660 Page 9715 Seat Heater: Description and Operation Heated Seats Description and Operation Battery positive voltage is supplied at all times to the heated seat module from the HTD SEAT fuse located in the rear fuse block. Ignition voltage is supplied to the heated seat switch and the heated seat module from the ROOF/HEAT SEAT fuse located in the BCM. When commanded ON, the heated seat module uses this voltage to heat the seat heating elements. The heated seat module and the seat heating elements are grounded through the module ground circuit to G303. Each time the heated seat switch is pressed, B+ is supplied to the heated seat module through the heated seat signal circuit. The module counts these inputs to determine what level of heat the vehicle operator is commanding. In response to these switch signals, the heated seat module closes it's contacts and applies battery positive voltage through the heated seat element supply voltage circuit to the seat heating elements. When the thermistor inside the seat cushion reaches a certain resistance, the control module open and close the supply voltage in order to maintain that heat level. Page 4299 9 - Torque Converter Assembly 10 - Park Pawl Actuator Assembly 11 - Fluid Pump Drive Link Assembly 12 - Park Pawl 13 - Front Differential Transfer Driven Gear 14 - Front Differential Drive Pinion Gear 15 - Park Gear 16 - Torque Converter and Support and Fluid Pump Housing Assembly 17 - Front Differential Carrier Assembly 18 - Front Differential Carrier Baffle 19 - Front Differential Ring Gear 20 - Front Differential Drive Pinion Gear Lube Tube 21 - 1-2-3-4 Clutch Assembly 22 Low and Reverse Clutch Assembly (OWC) 23 - Low and Reverse Clutch 24 - 2-6 Clutch Assembly 25 - 3-5-Reverse Clutch Assembly 26 - 4-5-6 Clutch Assembly 27 - Input Speed Sensor 28 - Case Cover Assembly 29 - Control Valve Body Cover 30 - Input Shaft Speed Sensor Reluctor Wheel 31 Control Valve Lower Body Assembly 32 - Control Valve Upper Body Assembly 33 - Control Valve Channel Plate Assembly 34 - Control Solenoid Valve Assembly (w/Body and TCM) 35 - Manual Valve Disassembled Views Disassembled Views Case and Associated Parts Page 4037 Page 5586 Speaker - Right Rear (UW5) Starter Generator X1 (KY1) Page 8207 Page 5584 Speaker - Right Front (UW5) Speaker - Right Front Tweeter Page 8680 4. Plug weld accordingly. 5. Clean and prepare all of the welded surfaces. 6. Install all of the related panels and components. 7. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (). 8. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems (See: Paint, Striping and Decals/Paint/Application and ID/Basecoat/Clearcoat Paint Systems). 9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 10. Enable the SIR system. Refer to SIR Disabling and Enabling (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). Page 8983 Front Floor Console Extension Panel Replacement - Right Side Front Floor Console Extension Panel Replacement - Right Side Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Page 5081 Alternator: Diagrams Component Connector End Views Generator X1 (LE5 or LE9) Generator X1 (LY7) 4T45-E - Automatic Transmission Transmission Mode Indicator - A/T: Service and Repair 4T45-E - Automatic Transmission Automatic Transmission Control Indicator Replacement Page 8184 Page 6066 within a second or 2. Circuit Protection - Fuses Circuit Protection - Fuses Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools. The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are a one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine if the element in the fuse is broken (2). If not broken (1), also check for continuity using a Digital Multimeter (DMM) or a continuity tester. If the element is broken or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links Circuit Protection - Fusible Links Special Tools EL 39200 - Digital Multimeter (DMM) Audio System - Noise When Using OnStar(R) Radio/Stereo Noise Filter: All Technical Service Bulletins Audio System - Noise When Using OnStar(R) TECHNICAL Bulletin No.: 07-08-46-002D Date: July 29, 2009 Subject: Audio Whine Noise from Radio Speakers When Using OnStar(R) (Install Noise Suppression Filter) Models: 2007-2010 GM Passenger Cars and Trucks (Including Saturn) 2007-2010 HUMMER H2, H3 2007-2009 Saab 9-7X Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 07-08-46-002C (Section 08 - Body and Accessories). Condition Some customers may comment on an audio whine coming from the radio speakers when using the OnStar(R) system. The amplitude and frequency of the whine will change with an increase or decrease in engine speed. Cause This condition may be caused by electrical noise on the OnStar(R) Vehicle Communication Interface Module (VCIM) battery feed wire being passed to the microphone output pins at the radio. Correction Technicians are to install a noise suppression filter, P/N 1224205, into the OnStar(R) battery voltage circuit, a few centimeters (inches) from the VCIM. The filter package has three attached wires - a single yellow wire at one end with a yellow wire and a black wire at the other. Install the single yellow wire side into the battery voltage circuit towards the VCIM. Install the remaining single yellow wire into the battery voltage circuit toward the fuse and the black wire to ground. Important The noise suppression filter is polarity sensitive. The filter is designed to be most effective when the end with the capacitor ground is connected towards the source of the electrical noise. Install the filter in this polarity first. If the noise level is still not satisfactory, try disconnecting the capacitor ground. In some cases, if the first installation does not correct the noise, try reversing the filter polarity (removing the filter, turning it end for end and then reinstalling it) and grounding the capacitor lead. Parts Information Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table above. Service and Repair Radiator Support: Service and Repair Front End Upper Tie Bar Replacement Removal Procedure Warning: Refer to Approved Equipment for Collision Repair Warning (See: Service Precautions/Technician Safety Information/Approved Equipment for Collision Repair Warning). 1. Disable the SIR system. Refer to SIR Disabling and Enabling (See: Interior Moulding / Trim/Dashboard / Instrument Panel/Air Bag(s) Arming and Disarming/Service and Repair). 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Remove all related panels and components. 4. Repair as much of the damage as possible to factory specifications. Refer to Dimensions - Body (). 5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair (). Page 9216 Power Door Lock Switch: Diagrams Component Connector End Views Door Lock Switch - Driver Door Lock Switch - Passenger Page 7739 Page 5118 Starter Motor: Service and Repair Starter Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Remove the flywheel inspection cover bolts. 4. Remove the flywheel inspection cover. 5. Remove the electrical connections from the starter motor. 6. Remove the starter motor mounting bolts. 7. Remove the starter motor. Installation Procedure Caution: Before installing the starter motor to the engine, tighten the nut next to the cap on the solenoid BAT terminal. If this terminal is not tight in the solenoid cap, the cap may be damaged during installation of electrical connections and cause the starter motor to fail later. 1. Install the starter motor to the engine. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Page 8582 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Page 7588 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Duct Air Temperature Sensor Replacement - Lower Removal Procedure 1. Remove the right front floor console extension panel. Refer to Front Floor Console Extension Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Extension Panel Replacement - Right Side). 2. Twist and pull the lower air temperature sensor from the center floor air outlet duct. 3. Remove the lower air temperature sensor wire harness. Installation Procedure 1. Install the lower air temperature sensor wire harness. Page 6549 Power Distribution Module: Diagrams Component Connector End Views Accessory AC/DC Power Control Module X1 (KV1) Accessory AC/DC Power Control Module X2 (KV1) Page 9159 Note: Ensure that the dress cover and connector body are both in the released position before reassembling. Failure to do so may cause damage to the connector and component. Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Delphi Connectors Delphi Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. Specifications Axle Nut: Specifications Front axle nut ....................................................................................................................................... .................................................... 215 Nm (159 lb ft) Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Page 5238 For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. Page 9648 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Page 2790 Page 1206 2. Coat the new filter O-ring seal with a small amount of petroleum jelly, and install the filter into the case. Caution: Push straight down on the center of the oil level control valve in order to prevent damage to the case bore. 3. Install the oil level control valve. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the oil pan gasket, the oil pan, and hand start the oil pan bolts. Tighten the oil pan bolts to 12 Nm (9 lb ft). 5. Lower the vehicle. 6. Refill transaxle using DEXRON(R) VI to the specified refill capacity. * The bottom pan removal capacity is approximately 6.5 L (6.9 qt). * The complete overhaul capacity is approximately 9 L (9.5 qt). * The dry capacity is approximately 12.2 L (12.9 qt). 7. Start the engine. Warm up the transaxle and check for leaks. 8. Check for proper fluid level. Refer to Transmission Fluid Level and Condition Check (See: Transmission and Drivetrain/Automatic Page 4949 16. Connect the RR brake pipe fitting (1) and tighten to 20 Nm (15 lb ft). 17. Connect the LR brake pipe fitting (1) and tighten to 20 Nm (15 lb ft). Page 6987 Second Design - Black Painted (DO NOT Lube) Hydraulic Assist Power Steering First Design - Bare Steel Tube (Lube OK) Second Design - Black Painted (DO NOT Lube) In the unlikely event that the source of the noise is identified as a second design shaft with black painted tube, it must be replaced. Correction 1 (Only for First Design - DO NOT USE FOR 2ND DESIGN) Lubricate the intermediate shaft with steering column shaft lubrication kit, P/N 26098237. 1. From inside the vehicle, remove the instrument panel insulator panel - left side panel to gain access to the intermediate shaft. 2. Remove the intermediate shaft to steering column attachment bolt. 3. Remove the intermediate shaft from the steering column. 4. Extend the intermediate shaft all the way. Using the intermediate shaft grease kit, P/N 26098237, inject the grease into the gap between the inner shaft and the outer shaft as you are collapsing the shaft. This will draw the grease into the shaft. 5. Cycle the shaft up and down several times to distribute the grease. Important Remove original thread locker material from the bolt and apply Loctite(R) 242 (or equivalent) to the threads of the bolt and reinstall intermediate shaft bolt. 6. Install the intermediate shaft to the column. Tighten - For electronic power steering, tighten the bolt to 49 Nm (36 lb ft). - For hydraulic power steering, tighten the bolt to 62 Nm (46 lb ft). Page 7021 Page 2494 Page 6491 Page 5503 Ho - In Component Connector End Views Hood Ajar Switch (AP3 or HP7) Page 6243 Digital Video Disc (DVD) Control Module X3 (SPO Accessory) (UJ5) Page 224 Page 3367 Disclaimer Page 8271 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 907 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (7) to the intake CMP sensor (6). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 10529 Horn Switch: Service and Repair Steering Wheel Horn Contact Replacement Page 6036 5. Use a small flat-blade tool to remove TPA from the connector. 6. Use the J 38125-213 or the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 7. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Page 4122 Shift Interlock Solenoid: Service and Repair Automatic Transmission Shift Lock Control Actuator Replacement Removal Procedure 1. Remove the automatic transaxle control assembly. 2. Disconnect the Shift Lock Control Solenoid connector from the solenoid. 3. Using a flat-blade screwdriver or similar tool pry the solenoid off of the ball-sockets on the solenoid plunger and solenoid body. Page 460 Page 2237 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 4. Install the upper exhaust manifold brace bolt (1) and tighten to 58 Nm (43 lb ft). 5. Tighten the exhaust manifold nuts in the sequence shown to 14 Nm (10 lb ft). 6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 7. If equipped with a LE5, install the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement (See: Exhaust Pipe/Service and Repair/Exhaust Manifold Pipe Replacement) 8. If equipped with a LAT, install the catalytic converter. Refer to Catalytic Converter Replacement (See: Catalytic Converter/Service and Repair/Catalytic Converter Replacement). 9. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Sensor 1 (See: Powertrain Management/Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor Replacement - Sensor 1). 10. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (See: Heat Shield/Service and Repair/Exhaust Manifold Heat Shield Replacement). Page 9921 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 5511 Ignition Coil 1 (LY7) Page 6163 Fuse Block - Underhood X1 Page 5748 Page 8515 Speaker - Right Rear (UW5) Page 3928 Procedures/4T45-E - Automatic Transmission/Transmission Fluid Level and Condition Check). Page 4762 7. Remove the brake pads (1) from the brake caliper mounting bracket (3). 8. Remove and the brake pad retainers (2) from the brake caliper mounting bracket (3). 9. Inspect the following brake components for damage and corrosion: * Brake caliper guide pin bolts * Brake caliper guide pins * Brake caliper guide pin bushing * Brake caliper bracket boots * Brake caliper bracket 10. Do not attempt to clean away any corrosion. If damaged or corroded replace the necessary components. Refer to Rear Brake Caliper Hardware Replacement (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Hardware Replacement), and Rear Brake Caliper Bracket Replacement (See: Brake Caliper/Service and Repair/Removal and Replacement/Rear Brake Caliper Bracket Replacement). 11. Inspect the brake caliper piston boot for deterioration, replace if damaged. Refer to Rear Brake Caliper Overhaul (See: Brake Caliper/Service and Repair/Overhaul/Rear Brake Caliper Overhaul). 12. Use a piston installation tool in order to twist the brake caliper piston into the brake caliper bore. Page 3816 7. Remove the 2 control valve body bolts (4) M6 x 65. 8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95. 10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body and transmission control module (TCM) assembly (5). Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 12. Remove the control solenoid valve assembly filter plate (6). * Discard the filler plate. It is not reusable. * Inspect the pressure switch manifold seals for damage or contamination. Replace the control solenoid valve assembly as necessary. * Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage around the PCS seals. Replace the upper channel plate as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (1). Page 5074 2. Slide the ECM/TCM bracket (2) into position on the battery tray. 3. Install the ECM/TCM bracket bolt (1) and tighten to 8 Nm (71 lb in). 4. Connect the engine wiring harness electrical connector (1) to the TCM. 5. Connect the engine wiring harness electrical connectors (2) to the ECM. 6. Install the engine wiring harness clips (3) to the ECM/TCM bracket (4). Page 3567 Camshaft Position (CMP) Sensor - Exhaust (LAT or LE5 or LE9) Page 5826 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Page 6169 Fuse Block - Underhood X4 Page 2870 1. While depressing the lock, remove the connector from the component. 2. Locate the two indents of the terminal position assurance (TPA) located on the bottom of the connector body. Page 9498 Page 7491 5. Remove the blower motor nuts. 6. Remove the blower motor from the blower motor cup. Installation Procedure 1. Install the new blower motor to the blower motor cup. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the blower motor nuts and tighten to 2.4 Nm (21 lb in). Page 24 Communications Control Module: Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 6762 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer A/T Controls - Downshift Hesitation/Delayed Shifting Control Module: Customer Interest A/T Controls - Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Engine Controls - Aftermarket Accessory Usage Engine Control Module: All Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Page 2435 Caution: Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. If reinstalling the original sensor, or if installing a NEW sensor without a sealer, coat the threads with sealant. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Engine, Cooling and Exhaust/Engine/Specifications/Adhesives, Fluids, Lubricants, and Sealers). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the ECT sensor (1) to the thermostat housing and tighten the sensor to 20 Nm (15 lb ft). 3. Connect the engine wiring harness electrical connector (1) to the ECT sensor (2). 4. Fill the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Page 10038 Page 886 Air Flow Meter/Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 5682 Page 2741 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Page 2671 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Service and Repair Parking Light Bulb: Service and Repair Parking and Turn Signal Lamp Bulb Replacement Locations Turn Signal Switch: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 6386 Radio X2 Page 4489 4. Insert the J 41545 as shown and rotate the switch until the tool drops onto position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Tighten the transaxle range switch bolts to 20 Nm (15 lb ft). 6. Remove the alignment tool. Warning Hold the transmission range selector lever while removing or installing the lever retaining nut. Failure to hold the lever can cause damage to the transmission internal park system components which could allow the vehicle to roll when placed in the park position. 7. Install the transaxle range switch lever and nut and tighten the nut to 35 Nm (26 lb ft). Page 7670 17. Install the liquid line bracket bolt and tighten to 10 Nm (89 lb in). 18. Install the refrigerant pressure sensor and tighten to 5 Nm (44 lb in). 19. Install the refrigerant pressure sensor wire harness connector. 20. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Service and Repair/Refrigerant Recovery and Recharging). 21. Leak test the fittings using the J 39400-A. 22. Install the surge tank to the surge tank bracket. Page 9549 After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. Locate the terminal position assurance (TPA). 4. Use a small flat-blade tool to push the TPA until it bottoms out. Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass airflow (MAF)/intake air temperature (IAT) sensor. 2. Loosen the air cleaner outlet duct clamp at the air cleaner assembly. 3. Remove the air cleaner outlet duct from the air cleaner assembly. 4. Disengage the air cleaner cover latches (1). 5. Open the air cleaner cover. 6. Remove and discard the air filter assembly. Installation Procedure Page 2299 Page 3514 Page 4459 Control Module: Service and Repair Control Solenoid Valve and Transmission Control Module Assembly Replacement Removal Procedure 1. Remove the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/6T70/6T75 - Automatic Transmission/Control Valve Body Cover Replacement). 2. Disconnect the input speed sensor electrical connector (1). 3. Disconnect the output speed sensor electrical connector (2). 4. Disconnect the shift position switch electrical connector (3). 5. Remove the 4 control valve body bolts (1) M6 x 80. 6. Position the control solenoid valve spring (8) to the side. Spring will be released with the removal of the control valve body assembly. 7. Remove the 2 control valve body bolts (4) M6 x 65. Page 6398 Seat Belt Retractor Pretensioner - Driver Seat Belt Retractor Pretensioner - Passenger Page 6403 Seat Rear Vertical Motor - Passenger (LTZ) Seat Recline Motor - Driver (LTZ) Page 881 1. Install the O-ring onto the VSS. 2. Install the output VSS into the transmission case. Caution: Refer to Fastener Caution 3. Install the VSS stud and tighten the stud to 12 Nm (106 lb in). 4. Install the VSS electrical harness retainer to the VSS stud. 5. Connect the VSS electrical connector. 6. Lower the vehicle. Page 4839 Note: The wear sensor equipped disc brake pad must be mounted inboard of the rotor with the leading edge of the sensor facing the brake rotor during forward wheel rotation, or at the top of the pad when installed in vehicle position. 6. Install the brake pads (2) to the brake caliper bracket. 7. Remove the support (1) and reposition the brake caliper over the brake pads and to the mounting bracket. Refer to Front Brake Caliper Replacement (See: Front Brake Caliper Replacement). Rear Brake Caliper Bracket Replacement Rear Brake Caliper Bracket Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which Page 4499 85 - Transaxle Oil Filter Assembly 86 - Oil Level Control Valve 87 - Transaxle Bottom Pan Gasket 88 - Transaxle Oil Pan 89 - Chip Collector Magnet 120 - Chip Collector Magnet (Some Models) 126 - Side Cover Stud 127 - Transmission Wiring Harness Assembly (Some Models) 128 - Electrical Connector Retaining Bracket (Some Models) Case and Associated Parts - L4 Hybrid 1 - Side Cover (Structural) 2 - Axle Oil Seal 3 - Side Cover Bolt 4 - Side Cover Stud 5 - Side Cover Gasket 6 - Side Cover Oil Level Control Gasket 7 - Thrust Washer (Side Cover to Driven Sprocket) 8 - Oil Pump Bolt 9 - Oil Pump Bolt 10 - Transaxle Oil Pump Assembly 11 - Transaxle Wiring Assembly 12 - TFP Manual Valve Position Switch Assembly Bolt 13 - TFP Manual Valve Position Switch Assembly 15 - Wiring Harness Bracket Bolt/Input Speed Sensor Bolt 51 - Transaxle Case 52 - Vent Cap 55 - Torque Converter Assembly 61 - Output Speed Sensor Stud 62 - Output Shaft Speed Sensor 63 - O-Ring Seal (Output Speed Sensor) Page 1862 5. Reposition the idler pulley (2) to release tension off the drive belt. 6. Remove the drive belt from under the middle idler pulley. 7. Remove the drive belt from the vehicle. Installation Procedure 1. Install and position the drive belt around all of the pulleys except for the middle idler pulley. 2. Install the drive belt under the middle idler pulley. 3. Reposition the idler pulley (2) to install the drive belt. 4. Install the drive belt under the middle idler pulley. 5. Ensure the drive belt tensioner idler pulley is fully seated against the drive belt. 6. Loosen the forcing bolt on the EN-48932 - compressor (1) and remove from the drive belt tensioner spring. 7. Ensure that the drive belt tensioner idler is fully seated against the drive belt. Page 7573 Control Module HVAC: Diagrams Component Connector End Views Blower Motor Control Module (C68) Service and Repair Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement Special Tools EN-42067 - Rear Main Seal Installer For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Removal Procedure 1. Remove the flywheel. Refer to Engine Flywheel Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair). Note: Do not damage the outside diameter of the crankshaft or chamber with any tool. 2. Pry out the crankshaft rear oil seal using a flat-bladed tool. Installation Procedure 1. Using the EN-42067 - installer, install a NEW crankshaft real oil seal. 2. Install the flywheel. Refer to Engine Flywheel Replacement (See: Transmission and Drivetrain/Flex Plate/Service and Repair). Page 9970 13. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve. 14. Using the heat torch, apply heat to the high temperature heat shrink tubing. 15. Gradually move the heat from the center to the open end of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. 16. Replace any reflective tape and clips that may have been remove during the repair. Repairing Damaged Wire Insulation Repairing Damaged Wire Insulation If the wire insulation has been chafed, or broken, enough to show the conductive portion of the wire, and the wire is not damaged, determine the length of insulation that needs to be repaired. If the repair is less than 280 mm (11 in), cut the wire within the damaged area. Then slide the appropriate heat shrink tubing (listed below) over the wire, and repair the wire by splicing the wires together. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Once the wire is spliced together slide heat shrink tubing over the damaged area and apply heat to seal the repaired wire. If the wire is damaged, or the damaged area is larger than 280 mm (11 in), then replace the damaged wire by splicing in a new section of wire. Refer to Splicing Copper Wire Using Splice Sleeves (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Splicing Copper Wire Using Splice Sleeves). Page 2150 Radiator Air Side Baffle and Deflector Replacement Radiator Air Side Baffle and Deflector Replacement Removal Procedure 1. Remove the upper front fascia. Refer to Front Bumper Fascia Replacement (See: Body and Frame/Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia Replacement). 2. Remove the lower radiator air baffle. Refer to Radiator Air Lower Baffle and Deflector Replacement (See: Radiator Air Lower Baffle and Deflector Replacement). Page 8233 View showing depressing of the lever lock release tab. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 7057 Note: Only move the tire enough to feel any lash between the inner tie rod and the inner tie rod housing without moving the steering gear rack. 6. Grasping the tire at the 3 o'clock (2) and 9 o'clock (1) positions, gently push in on one side of the tire in order to remove any lash. 7. Zero the J-8001 - Dial Indicator. 8. On the same side of the tire previously pushed in, gently pull out and measure the lash. 9. Record the measurement seen on the J-8001 - Dial Indicator. 10. If the measured value exceeds 0.5 mm (0.02 in), replace the inner tie rod. Refer to Steering Linkage Inner Tie Rod Replacement (See: Service and Repair/Steering Linkage Inner Tie Rod Replacement). 11. Repeat the procedure for the other side. Page 548 Seat Adjuster Switch - Driver (without LTZ and AG1) Page 2493 Heated Oxygen Sensor (HO2S) 2 (LAT or LE5 or LE9) Tread Wear Indicators Description Tires: Description and Operation Tread Wear Indicators Description Tread Wear Indicators Description The original equipment tires have tread wear indicators that show when you should replace the tires. The location of these indicators are at 60 degree intervals around the outer diameter of the tire. The indicators appear as a 6 mm (0.25 in) wide band when the tire tread depth becomes 1.6 mm (2/32 in). Page 3829 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/4T45-E - Automatic Transmission/Control Valve Body Cover Replacement) 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/4T45-E - Automatic Transmission/Control Valve Body Cover Replacement). Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and Operation/4T45-E - Automatic Transmission/Transmission Adaptive Functions). Page 836 Page 5234 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 7295 * Uneven braking action * Steering lead * Imprecise vehicle handling Service and Repair Vacuum Pump: Service and Repair Power Brake Booster Vacuum Check Valve and Hose Replacement Removal Procedure 1. Without disconnecting the hoses, position the radiator surge tank aside. Refer to Radiator Surge Tank Replacement (See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/Radiator Surge Tank Replacement). 2. Disconnect the brake booster vacuum check valve (1) from the brake booster. 3. If the vacuum check valve (1) needs to be separated from the vacuum hose (3), release and reposition the clamp (2) on the vacuum hose (3) and remove the check valve (1) from the hose (3). 4. If replacing the vacuum check valve (1), remove the grommet (4) from the brake booster and discard the grommet. 5. If removing the vacuum hose (2), take note of the vacuum hose routing then disconnect from the engine intake manifold connection (3) by releasing tension on the vacuum hose clamp (1) and sliding the vacuum hose (2) off the intake manifold connection (3). Page 6730 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 3858 movement. 1. Remove the transmission side cover. 2. Remove the 2-3 shift solenoid retainer clip (304), the 2-3 shift solenoid (305) with O-ring (303), the 2-3 shift valve (307), and the 2-3 shift valve spring (306). Installation Procedure 1. Install the 2-3 shift valve spring (306), the 2-3 shift valve (307), the 2-3 shift solenoid (305) with O-ring (303) and the 2-3 shift solenoid retainer clip (304). 2. Install the transmission side cover. Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions See: Description and Operation. Page 6931 2. Use a deep socket to evenly press the power steering pump shaft seal into the power steering pump housing. 3. If necessary, install the power steering pump. Refer to Power Steering Pump Replacement (See: Service and Repair/Power Steering Pump Replacement). Page 10097 Sumitomo Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. Disconnect the connector from the component. Page 285 Page 9126 Page 7844 Attach Driver's Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the driver seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. Owner Letter Owner Letter March 2011 Page 4457 Page 326 For vehicles repaired under warranty use the table above. Disclaimer Page 9870 Page 1262 12. Install the compressor hose and liquid line connector. 13. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery and Recharging). 14. Leak test the fittings using the J 39400-A. 15. Install the surge tank to the surge tank bracket. Page 9179 5. Using terminal tool J-38125-11A or equivalent, remove the TPA by lifting straight off the connector body. 6. Using terminal release tool J-38125-215A, place the tip of the tool on the outside edge next to the terminal and depress the lock tab and remove the rear of the connector body. Terminal Repair Procedure Use the appropriate terminal and crimper in the J-38125 in order to replace the terminal. Yazaki Connectors Yazaki Connectors Special Tools J-38125 Terminal Repair Kit Page 594 Lateral Accelerometer: Service and Repair Vehicle Yaw Sensor with Vehicle Lateral Accelerometer Replacement Page 8411 Disclaimer Page 9388 Head Rest: Service and Repair Driver or Passenger Seat Head Restraint Replacement Driver or Passenger Seat Head Restraint Replacement Page 7288 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Page 2773 4. Disconnect the engine wiring harness electrical connectors (2) from the ECM. 5. Remove the engine wiring harness clips (3) from the ECM bracket (4). Caution: Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables or when charging the vehicles battery. 6. Gently lift the ECM retainers (1) up, disengaging the retainers from the ECM (2). 7. Tilt the ECM towards the engine and remove the ECM (2) from the bracket. Installation Procedure Page 9867 Page 4732 4. Install the park brake cable to the caliper. 5. Remove the caps or plugs from the brake caliper opening and the brake hose. Note: DO NOT reuse the copper brake hose gaskets. 6. Install NEW copper brake hose gaskets to the brake hose-to-caliper bolt and to the brake hose. 7. Install the brake hose and the brake hose-to-caliper bolt to the brake caliper and tighten the bolt to 50 Nm (37 lb ft). 8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (See: Brake Bleeding/Service and Repair/Hydraulic Brake System Bleeding). 9. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 10. Slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 9 and 10 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 12. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 13. Lower the vehicle. 14. Apply and release the park brake lever 4 times. Page 2887 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 991 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Page 9192 If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the Page 6905 7. Remove the power steering hose bracket nut (2) and bracket (1). 8. Disconnect the power steering gear inlet hose from the power steering pump. 9. Disconnect the power steering gear inlet pipe hose retainers. 10. Remove the steering gear. Refer to Steering Gear Replacement (See: Steering Gear/Service and Repair/Steering Gear Replacement). Page 2353 Engine Control Module (ECM) X1 (LZ4 or LZE) Page 2642 Disclaimer Page 17 Vehicle Communication Interface Module (VCIM) X3 (UE1) Page 3590 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 5246 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 10039 Page 3850 1 - Control Valve Body Cover Assembly 2 - Transmission Fluid Level Indicator Assembly 3 - Fluid Level Indicator Tube - Model Dependent 4 - Fluid Level Indicator Tube Seal - Model Dependent 5 Control Valve Body Cover Assembly Gasket 6 - Control Valve Body Cover Stud 7 - Control Valve Body Cover Bolt 8 - Control Valve Body Bolt 9 - Control Valve Body Bolt 10 - Control Valve Body Cover Wiring Connector Hole Seal 11 - Control Solenoid Valve Spring 12 - Control Valve Body Bolt 13 - Control Valve Body Bolt 14 - Control Valve Body Bolt 15 - Control Solenoid (w/Body and TCM) Valve Assembly 16 - Control Solenoid (w/Body and TCM) Filter Plate Assembly 17 - Manual Shaft Detent Assembly 18 - Control Valve Body Assembly 19 - A/Trans Output Speed Sensor Assembly 20 - A/Trans Output Speed Sensor Bolt 21 - A/Trans Case Assembly 22 - Torque Converter Housing Outer Seal 23 - Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly 24 Front Differential Drive Pinion Gear Lube Tube Page 6070 If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. * To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J-38125. High Temperature Wiring Repairs High Temperature Wiring Repairs Special Tools J-38125 Terminal Repair Kit High Temperature Wiring Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following: * Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire. * Replace any heat shielding that is removed. * Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit). * After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source. Identifying High Temperature Wiring Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust manifolds, catalytic converter, and exhaust pipes. The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items: * DuraSeal splice sleeves to crimp and seal connections * High temperature SCT1 shrink tubing to protect the splice sleeves * A large sampling of common electrical terminals * The correct crimp tool to attach the terminals to the wires * The correct tools to remove the terminals from the connectors The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair. High Temperature Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of the Page 10375 Page 2826 Locations Camshaft Position Sensor: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch Page 6461 Accelerator Pedal Position (APP) Sensor Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor Replacement - Intake Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (7) from the intake camshaft position (CMP) sensor (6). 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. Installation Procedure Page 7560 connector housing. Refer to Repairing Connector Terminals in SI. 15. Insert the wire into the new conduit and tape the conduit end at the connector. Tape the conduit closed every 255 mm (10 in) with electrical tape. 16. Connect the fan end electrical connector into the cooling fan. 17. Fasten the new wire and conduit with tie wraps (GM P/N 12337820), as shown below. At the cooling fan end of the wire and conduit, leave adequate slack to allow for engine movement (white tie wraps are used for display purposes, use black tie wraps to match the original appearance). With RPO LY7 - Fasten the new wire and conduit to the existing harness with wire tie wraps as shown. With RPOs LZ9, LZ4 or LZE - Fasten the new wire and conduit to metal the transmission cooler lines as shown. (The lower cover has been removed to show the location of the wire tie wraps.) 18. Trim the wire and conduit to length at the underhood fuse block area. 19. Obtain the terminals listed below from the J 38125 Terminal Repair Kit. 20. Strip the wire insulation as required and install the terminal, GM P/N 15324340, on the wire. Refer to Repairing Connector Terminals in SI. 21. Reinstall the terminal into A2 on the junction block. Reinstall the TPA and the harness back cover. 22. Reconnect the harness to the under hood fuse block. Refer to Electrical Center Identification Views, Fuse Block Underhood Bottom View in SI. 23. Reinstall the underhood fuse block into it's mounting base. Refer to Underhood Electrical Center or Junction Block Replacement in SI. Install the 40-amp fuse, GM P/N 15319478. 24. Reinstall the battery. Refer to Battery Replacement in SI. 25. Reinstall the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI. 26. Reinstall the windshield washer fill tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement in SI. 27. Confirm the high speed cooling fan operation using the Tech 2(R). Parts Information Page 5496 Heated Seat Control Module - Driver X3 (KA1) Page 5617 Wheel Speed Sensor (WSS) - Left Rear Wheel Speed Sensor (WSS) - Right Front Page 5333 Fuse Block - Underhood Bottom View Page 738 Fog/Driving Lamp Switch: Diagrams Component Connector End Views Fog Lamp Switch (T96) Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection Important: Before replacing any engine mount due to suspected fluid loss, verify that the source of the fluid is the engine mount, not the engine or accessories. 1. Install the engine support fixture. Refer to Engine Support Fixture (See: Service and Repair/Removal and Replacement/Engine Support Fixture). 2. Raise the engine slightly and observe the engine mount. Raising the engine removes the weight from the engine mount and creates a slight tension on the rubber portion. 3. Replace the engine mount if the engine mount exhibits any of the following conditions: * The hard rubber is covered with heat check cracks. * The rubber is separated from the metal plate of the engine mount. * The rubber is split through the center of the engine mount. * The engine mount itself is leaking fluid. 4. For engine mount replacement. Refer to Engine Mount Replacement (See: Service and Repair/Engine Mount Replacement). Page 9734 Heated Seat Control Module - Passenger X3 (KA1) Page 9149 The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the mating terminals of the connector. Connector Repairs Connector Repairs Connector Repairs contains a list of all connector repairs. The connector repairs are listed by the connector manufacturer and then by connector type. If the technician cannot identify the manufacturer of the connector, refer to Identifying Connectors below. Knowing the connector manufacturer will assist in finding the correct connector repair from the following list: * Connector Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Position Assurance Locks) * Terminal Position Assurance Locks (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Terminal Position Assurance Locks) * AFL/EPC Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/AFL/EPC Connectors) * Bosch Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Bosch Connectors) * Delphi Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Delphi Connectors) * FCI Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/FCI Connectors) * JST Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/JST Connectors) * Kostal Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Kostal Connectors) * Molex Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Molex Connectors) * Sumitomo Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Sumitomo Connectors) * Tyco/AMP Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Tyco/AMP Connectors) * Yazaki Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Yazaki Connectors) * Repairing Connector Terminals (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Repairing Connector Terminals) Connector Anatomy Page 2473 Manifold Pressure/Vacuum Sensor: Diagrams Component Connector End Views Manifold Absolute Pressure (MAP) Sensor (LAT or LE5 or LE9) Manifold Absolute Pressure (MAP) Sensor (LY7) Page 9317 2. Position the sunshade stop to the sunroof cable drive tube retainer. 3. Firmly press the sunshade stop onto the retainer. 4. Install the headliner. Refer to Headlining Trim Panel Replacement (See: Interior Moulding / Trim/Headliner/Service and Repair). Page 7777 Solar Sensor: Diagrams Component Connector End Views Sunload Sensor (C68) Page 4353 4. Once communication is established and you select the file you want to upload, you will see a screen similar to below. You can email the file directly from TIS2WEB by going to the Snapshot drop down menu and selecting "Send to e-mail" as shown in Figure 11. Figure 12 5. After selecting Send to e-mail, a dialog box like the one shown in Figure 12 will be displayed. Fill in the information as requested and then click send. Include the VIN in the subject line. 6. After all the information is entered, hit the send button. After sending the file, you will receive a confirmation box letting you know the e-mail was sent successfully. 7. It is recommended to now save the file to your computer using the same procedure as if you were using TIS 2000 in case your recipient doesn't receive your email with the snapshot data. Important Sending the file via e-mail through TIS2WEB does NOT save the file locally and there is no way to access your sent mail in TIS2WEB like a regular e-mail program. Sending a Snapshot to GM TAC Page 4814 - Left rear 11. Perform the automated bleed procedure as instructed by the scan tool. 12. If the automated bleed procedure is aborted, a malfunction exists. If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List - Vehicle ( See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions/Diagnostic Trouble Code (DTC) List - Vehicle) to diagnose the DTC. 13. After completion of the automated bleed procedure, press and hold the brake pedal to inspect for pedal firmness. 14. If the brake pedal feels spongy, repeat the bleed procedure completely. 15. Remove the scan tool. 16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 17. Lower the vehicle. 18. Adjust the brake fluid level. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures/Master Cylinder Reservoir Filling). 19. Road test the vehicle while confirming the brake pedal remains high and firm. Page 4597 2. Install the control solenoid valve body and TCM assembly (5). 3. Rotate the control solenoid valve spring (7) into position. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Install all bolts before tightening, then tighten in specified sequence. 4. Install the 4 control valve body bolts (1) M6 x 80. 5. Install the control valve body bolt (6) M6 x 55. 6. Install the 3 control valve body bolts (2) M6 x 95. 7. Install the control valve body bolt (3) M6 x 42. 8. Install the 2 control valve body bolts (4) M6 x 65 and tighten to 12 Nm (106 lb in). 9. Connect the input speed sensor electrical connector (1). 10. Connect the output speed sensor electrical connector (2). 11. Connect the shift position switch electrical connector (3). 12. Install the control valve body cover. Refer to Control Valve Body Cover Replacement (See: Automatic Transmission/Transaxle/Valve Locations Control Assembly: Locations Instrument Panel/Center Console Component Views Instrument Panel Components 1 - Turn Signal/Multifunction Switch 2 - Automatic Transmission Manual Shift Switch - Left (KB7) 3 - Instrument Panel Cluster (IPC) 4 - Automatic Transmission Manual Shift Switch - Right (KB7) 5 Steering Wheel Control Switch - Right 6 - Windshield Wiper/Washer Switch 7 - Ignition Switch 8 Sunload Sensor (C68)/Ambient Light Sensor (C60) 9 - Radio 10 - HVAC Control Module 11 Inflatable Restraint I/P Module Indicator 12 - Traction Control Switch (TCS) 13 - Accessory Power Outlet - I/P 14 - Accessory Power Outlet - 110V AC (KV1) 15 - Accessory Power Outlet - Center Console 16 - Hazard Warning Switch Page 4082 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Page 8265 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 7756 Discharge Air Temperature Sensor / Switch: Service and Repair Duct Air Temperature Sensor Replacement - Lower Duct Air Temperature Sensor Replacement - Lower Removal Procedure 1. Remove the right front floor console extension panel. Refer to Front Floor Console Extension Panel Replacement - Right Side (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Extension Panel Replacement - Right Side). 2. Twist and pull the lower air temperature sensor from the center floor air outlet duct. 3. Remove the lower air temperature sensor wire harness. Installation Procedure 1. Install the lower air temperature sensor wire harness. Page 3563 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 6512 X207 Inline Harness Connector End Views X207 I/P Harness to Body Harness Page 582 1. Align the brake fluid level sensor to the master cylinder reservoir. 2. Press the brake fluid level sensor into the master cylinder reservoir, ensure the retaining tabs click into place. 3. Connect the electrical connector to the brake fluid level sensor. Tread Wear Indicators Description Tires: Description and Operation Tread Wear Indicators Description Tread Wear Indicators Description The original equipment tires have tread wear indicators that show when you should replace the tires. The location of these indicators are at 60 degree intervals around the outer diameter of the tire. The indicators appear as a 6 mm (0.25 in) wide band when the tire tread depth becomes 1.6 mm (2/32 in). Page 8224 Disconnect the connector and probe the terminals from the mating side (front) of the connector. Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Note: When probing female 0.64 terminals, it is important to use the correct adapter. There have been some revisions to the test adapter for 0.64 terminals. The proper adapter for 0.64 terminals is the J-35616-64B which has a gold terminal and a black wire between the base and tip. Failure to use the proper test adapter may result in damage to the terminal being tested and improper diagnosis. Note: The proper adapter for probing the terminals for fuses, relays, or diodes in an electrical center is J-35616-35. Using any other tool or adapter may damage the terminal being tested. Refer to the following table as a guide in selecting the correct test adapter for front probing connectors: Backprobe Note: * Backprobe connector terminals only when specifically required in diagnostic procedures. * Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire Page 3239 1. Install the O-ring onto the VSS. 2. Install the output VSS into the transmission case. Caution: Refer to Fastener Caution 3. Install the VSS stud and tighten the stud to 12 Nm (106 lb in). 4. Install the VSS electrical harness retainer to the VSS stud. 5. Connect the VSS electrical connector. 6. Lower the vehicle. 6T30/6T40/6T45 - Automatic Transmission Shift Solenoid: Specifications 6T30/6T40/6T45 - Automatic Transmission Shift Solenoid Valve State and Gear Ratio Page 9904 Radiator Center Grille Replacement Grille: Service and Repair Radiator Center Grille Replacement Radiator Center Grille Replacement Page 6814 The D height dimension measurement determines the proper rear end ride height. There is no adjustment procedure. Repair may require replacement of suspension components. Use the following procedure to check the D dimension: 1. With the vehicle on a flat level surface, lift upward on the rear bumper 38 mm (1.59 in). 2. Gently remove your hands and allow the vehicle to settle. 3. Repeat the jouncing operation 2 more times. 4. Measure the vertical distance from the bottom surface of the floor pan to the top surface of the control arm flange. 5. Repeat this task for the other side of the vehicle. 6. Using your hands, jounce the front of the vehicle downward approximately 38 mm (1.59 in). 7. Gently remove your hands and allow the vehicle to settle. 8. Repeat the jouncing operation 2 more times. 9. Measure the D height dimension. 10. The true D height dimension number is the average of the high and the low measurements. Refer to Trim Height Specifications (See: Suspension/Specifications/Mechanical Specifications/Trim Height Specifications). 11. If these measurements are out of specifications, inspect for the following conditions: * Worn or damaged suspension components * Collision damage Page 1251 Hose/Line HVAC: Service and Repair Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement Special Tools J 39400-A Halogen Leak Detector Removal Procedure 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery and Recharging). 2. Remove the refrigerant pressure sensor wire harness connector. 3. Remove the refrigerant pressure sensor. 4. Remove the liquid line bracket bolt. 5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (See: Filters/Air Cleaner Housing/Service and Repair). 6. Remove the surge tank from the surge tank bracket. 7. Remove the suction hose and liquid line nut from the thermal expansion valve (TXV). 8. Remove the suction hose and liquid line from the TXV. Page 2200 Water Pump: Service and Repair Water Pump Replacement Removal Procedure 1. Drain the cooling system. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). 2. Loosen the water pump pulley bolts. 3. Remove the drive belt. Refer to Drive Belt Replacement (See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair). 4. Remove the water pump pulley bolts and pulley. 5. Remove the water pump bolts. 6. Remove the water pump and gasket. 7. Clean the water pump mating surfaces. Page 902 Camshaft Position (CMP) Sensor - Exhaust (LAT or LE5 or LE9) Page 2162 Radiator Hose: Service and Repair Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement Special Tools J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the coolant. Refer to Cooling System Draining and Filling (See: Service and Repair/Cooling System Draining and Filling). 2. Reposition the radiator outlet hose clamp at the radiator using the J 38185. 3. Remove the radiator outlet hose from the radiator. 4. Reposition the radiator outlet hose clamp at the engine using the J 38185. 5. Remove the radiator outlet hose from the engine. 6. Remove the radiator outlet hose clamps from the radiator outlet hose. Installation Procedure 1. Install the radiator outlet hose clamps to the radiator outlet hose. Page 8794 Door Latch - Right Rear Page 8095 Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). Note: Do not damage the exterior surface of the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use general purpose cleaner to clean the leak area. 9. Apply 3 mm (0.12 in) thick layer of adhesive/sealant to the leak area. Refer to Adhesives, Fluids, Lubricants, and Sealers (See: Suspension/Specifications/Fluid Type Specifications). 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 13. Pressurize the tire to 276 kPa (40 psi). 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Inflate the tire to the specified pressure as stated on the tire placard. 16. Balance the tire and wheel. Refer to Tire and Wheel Assembly Balancing - Off Vehicle (See: Body and Frame/Testing and Inspection/Vibration Diagnosis and Correction/Repair Instructions/Tire and Wheel Assembly Balancing - Off Vehicle). 17. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Page 4962 Page 2885 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Page 2958 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 1. Install the engine oil pressure switch. Tighten the switch to 22 Nm (16 lb ft). 2. Connect the engine wiring harness electrical connector (2) to the oil pressure switch. 3. Install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). Page 888 Air Flow Meter/Sensor: Service and Repair Mass Airflow Sensor with Intake Air Temperature Sensor Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF)/intake air temperature (IAT) sensor (2). 2. Remove the MAF/IAT sensor screws (1). 3. Remove the MAF/IAT sensor (2). Installation Procedure Page 6091 Auxiliary Power Outlet: Testing and Inspection Power Outlet Receptacle Malfunction Power Outlet Receptacle Malfunction Diagnostic Instructions * Perform the Diagnostic System Check - Vehicle (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic System Check - Vehicle) prior to using this diagnostic procedure. * Review Strategy Based Diagnosis (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Strategy Based Diagnosis) for an overview of the diagnostic approach. * Diagnostic Procedure Instructions (See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Procedure Instructions) provides an overview of each diagnostic category. Diagnostic Fault Information Circuit/System Description The accessory DC/AC power inverter module converts 12 V direct current (DC) battery voltage to 110 V at 60 Hertz (Hz) alternating current (AC) in order to operate AC powered devices. The accessory DC/AC power inverter module provides up to 150 watts of power. The accessory DC/AC power inverter module is connected to a chassis ground circuit and receives fuse protected battery voltage. The accessory power receptacle - 110 V AC has an internal switch, that detects when an AC powered device is plugged into the receptacle. When the ignition is ON and an AC powered device is plugged into the accessory power receptacle - 110 V AC, the normally open switch in the accessory power receptacle - 110 V AC, closes. When the accessory DC/AC power inverter module detects the voltage from the accessory power receptacle - 110 V AC switch, the inverter module begins to supply 110 V AC to the accessory power receptacle - 110 V AC after a 1.5 second delay. Reference Information Schematic Reference Cigar Lighter/Power Outlet Schematics (See: Diagrams/Electrical Diagrams) Connector End View Reference Component Connector End Views (See: Diagrams/Connector Views/Connector End Views By Name) Description and Operation Power Outlets Description and Operation (See: Description and Operation) Electrical Information Reference * Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) * Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) * Testing for Intermittent Conditions and Poor Connections (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Intermittent Conditions and Poor Connections) * Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) Circuit/System Verification Warning Page 2567 Knock Sensor: Service and Repair Knock Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (1) from the knock sensor pigtail electrical connector (6). 4. Remove the knock sensor electrical connector pigtail (6) clip from the oil level indicator tube bracket. 5. Remove the knock sensor bolt. 6. Remove the knock sensor. Installation Procedure Page 9776 Page 8043 Disclaimer Page 3632 1 - Control Valve Body Cover Assembly 2 - Transmission Fluid Level Indicator Assembly 3 - Fluid Level Indicator Tube - Model Dependent 4 - Fluid Level Indicator Tube Seal - Model Dependent 5 Control Valve Body Cover Assembly Gasket 6 - Control Valve Body Cover Stud 7 - Control Valve Body Cover Bolt 8 - Control Valve Body Bolt 9 - Control Valve Body Bolt 10 - Control Valve Body Cover Wiring Connector Hole Seal 11 - Control Solenoid Valve Spring 12 - Control Valve Body Bolt 13 - Control Valve Body Bolt 14 - Control Valve Body Bolt 15 - Control Solenoid (w/Body and TCM) Valve Assembly 16 - Control Solenoid (w/Body and TCM) Filter Plate Assembly 17 - Manual Shaft Detent Assembly 18 - Control Valve Body Assembly 19 - A/Trans Output Speed Sensor Assembly 20 - A/Trans Output Speed Sensor Bolt 21 - A/Trans Case Assembly 22 - Torque Converter Housing Outer Seal 23 - Front Differential Drive Pinion (w/Transfer Gear) Gear Assembly 24 Front Differential Drive Pinion Gear Lube Tube Page 4981 1. Align the brake fluid level sensor to the master cylinder reservoir. 2. Press the brake fluid level sensor into the master cylinder reservoir, ensure the retaining tabs click into place. 3. Connect the electrical connector to the brake fluid level sensor. Page 2410 Battery Current Sensor: Diagrams Component Connector End Views Battery Current Sensor (LAT or LE5 or LY7 or LE9) Page 249 Fuse Block - Rear X4 Locations Fuel Tank Pressure Sensor: Locations Wheels/Vehicle Underbody Component Views Fuel Tank Components 1 - Evaporative Emission (EVAP) Canister 2 - Evaporative Emission (EVAP) Canister Vent Solenoid Valve 3 - Fuel Pump and Sender Assembly 4 - Fuel Tank Pressure (FTP) Sensor 5 - Fuel Tank Page 2230 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Side Exhaust Manifold Replacement - Right Side Special Tools J 39194-B Heated Oxygen Sensor Socket Removal Procedure Caution: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect proper operation of the oxygen sensor. Caution: The use of excessive force may damage the threads in the exhaust manifold/pipe. Note: The in-line connector and louvered end must be kept clear of grease, dirt or other contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the heated oxygen sensor (HO2S). Note: The HO2S may be difficult to remove when the engine temperature is less than 48°C (120°F) 1. Remove the generator. Refer to Generator Replacement (See: Starting and Charging/Charging System/Alternator/Service and Repair/Generator Replacement). 2. Remove the connector position assurance (CPA) retainer (3). 3. Disconnect the engine wiring harness electrical connector (2) from the HO2S electrical connector. 4. Remove the HO2S electrical connector rosebud clip (1) from the ignition coil bracket. Specifications Flex Plate: Specifications Flex plate ............................................................................................................................................. ........................................... 53 Nm (39 lb ft) plus 25° Page 4336 Installation Procedure Note: The holes in the control valve body cover wiring connector hole seal must face toward the control solenoid valve assembly. If the holes face toward the valve body cover, there is a potential for a leak around the seal. 1. Install the control valve body cover wiring connector hole seal. 2. Install the control valve body cover gasket to the control valve body cover. 3. Install the control valve body cover. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Note: Install all control valve body cover bolts and studs by hand then torque all bolts and studs in sequence. 4. Install the top 3 control valve body cover bolts (1) M6 x 30. 5. Connect the transmission wire harness retainer to the bracket on top of the transmission. 6. Raise the vehicle. 7. Install the 9 lower control valve body cover bolts (1) M6 x 30. 8. Install the 2 control valve body cover studs (2) M6 x 30. 9. Tighten the 12 bolts and 2 studs in sequence to 12 Nm (106 lb in). Page 9885 Page 5714 X800 Inline Harness Connector End Views X800 Body Harness to Right Rear Door Harness Page 5571 Seat Front Vertical Motor - Driver Seat Front Vertical Motor - Passenger Page 2627 1. Install the MAF/IAT sensor (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the MAF/IAT sensor screws (1) and tighten to 2.5 Nm (22 lb in). 3. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor (2). Page 6393 Repeater Lamp - Right Front Se - St Page 1692 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Note: * If the wheels are chrome-plated, do not re-plate or refinish the wheels. * If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: * Corrosion * Scrapes * Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Warning To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: * Lubricants * Wax * Dirt Note: * Do not re-machine the wheel. * Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Note: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Note: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. Refer to Tire Dismounting and Mounting (See: Tires/Service and Repair/Removal and Replacement). 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: * Corrosion * Overspray * Dirt 13. Install the tire and wheel assembly to the vehicle. Refer to Tire and Wheel Removal and Installation (See: Service and Repair). Lighting - Low Beam Headlamp(s) Inoperative Wiring Harness: All Technical Service Bulletins Lighting - Low Beam Headlamp(s) Inoperative TECHNICAL Bulletin No.: 10-08-42-001 Date: May 14, 2010 Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) Models: 2008-2010 Buick Enclave 2008-2010 Cadillac CTS, CTS-V 2010 Cadillac CTS Sport Wagon, SRX 2007-2010 Cadillac Escalade, Escalade ESV, Escalade EXT 2007-2010 Chevrolet Avalanche, Silverado, Suburban, Tahoe 2008-2010 Chevrolet Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL 2006-2010 Pontiac G6 2007-2010 Saturn AURA Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps. Condition Some customers may comment that the low beam headlamp is inoperative. Correction DO NOT replace the entire headlamp assembly for this condition. Replace the bulb and inspect the connector following the procedure below. 1. Remove the lamp assembly, then remove the bulb. Refer to Headlamp Assembly Replacement in SI. 2. Inspect the connector. - If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog. - If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb. Important Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures. 1. Cut the wires of the connector approximately 45 mm (1-3/4 in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing. 2. Replace the bulb. 3. Verify that the headlamp is fully functional. Parts Information Warranty Information For vehicles repaired under warranty, use: Page 3228 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 3748 - Select Fuel Composition Reset (F1). - The first parameter is "Fuel Alcohol Content" displayed as a percentage. If the Fuel Alcohol Content percentage is above 25%, this is the probable cause of DTC P0172. - From this screen the "Fuel Alcohol Content" can be reset to zero by pressing the lower right Tech 2(R) button. It will then display 0% when it's reset. Finally, reprogram the PCM with the latest calibration. This will correct for the PCM alcohol calculations. Note The PCM must be reset from this screen. It does not reset to zero when the PCM is reprogrammed. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Page 1254 19. Remove the liquid line. Note: Cap all A/C components immediately to prevent system contamination. 20. Remove and discard the sealing washers. Installation Procedure 1. Uncap A/C components. 2. Install new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Heating and Air Conditioning/Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 3. Install the liquid line. 4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Vehicle Lifting/Service and Repair). Page 2210 5. Remove the exhaust manifold heat shield bolts and shield. 6. Remove the left (front) catalytic converter nuts (1) at the exhaust manifold. 7. Remove the muffler assembly. Refer to Exhaust Muffler Replacement (See: Muffler/Service and Repair). Page 9488 Page 4834 9. Remove the brake caliper guide pins (2) from the brake caliper mounting bracket (4). 10. Remove the caliper pin boots (3) from the brake caliper mounting bracket (4). Installation Procedure 1. Apply a thin coat of high temperature silicone lube to the brake caliper guide pin boots. 2. Install the brake caliper pin boots (3) to the brake caliper mounting bracket (4). 3. Apply a thin coat of high temperature silicone lube to the brake caliper guide pins (2). 4. Install the brake caliper guide pins (2) to the brake caliper mounting bracket (4). 5. Install the brake pad retainers (2) to the brake caliper mounting bracket (3). 6. Install the brake pads (1) to the brake caliper mounting bracket (3). 7. Install the brake caliper to the brake caliper mounting bracket. Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass airflow (MAF)/intake air temperature (IAT) sensor. 2. Loosen the air cleaner outlet duct clamp at the air cleaner assembly. 3. Remove the air cleaner outlet duct from the air cleaner assembly. 4. Disengage the air cleaner cover latches (1). 5. Open the air cleaner cover. 6. Remove and discard the air filter assembly. Installation Procedure Page 6865 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become UN-centered and cause possible damage to the SIR coil. If you think the SIR coil has became UN-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Page 1841 2. Install the valve spring (3) and retainer (2). 3. Compress the valve spring using the valve spring compressor. 4. Install the valve spring keepers (1). 5. Disconnect the air hose and air hose adapter. 6. Remove the EN-43649 - compressor and EN-43649-10 - adaptor set from the cylinder head. 7. Install the spark plugs. Refer to Spark Plug Replacement (See: Tune-up and Engine Performance Checks/Spark Plug/Service and Repair). Page 5222 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 10737 Page 6432 Theft Deterrent Module (TDM) Page 10457 Ambient Light Sensor: Diagrams Component Connector End Views Ambient Light Sensor (C60) Page 10026 Page 5108 Keyless Start Transmitter: Technical Service Bulletins Keyless Start - 2-Way Advanced Remote Start INFORMATION Bulletin No.: 09-00-89-025A Date: October 26, 2009 Subject: GM Accessories: 2-Way Advanced Remote Start Systems Part Information Models: 2007-2010 Buick Lucerne 2008-2010 Buick Enclave 2007-2010 Cadillac Escalade ESV, EXT 2008-2010 Cadillac DTS 2007-2009 Chevrolet Equinox, HHR 2007-2010 Chevrolet Avalanche, Cobalt, Silverado, Tahoe 2008-2010 Chevrolet Impala, Malibu 2009-2010 Chevrolet Traverse 2007-2010 GMC Acadia, Sierra, Yukon 2008-2010 HUMMER H2 2007-2009 Pontiac Torrent 2007-2010 Pontiac G5, G6 2008-2010 Pontiac G8 2010 Pontiac Solstice 2007-2010 Saturn AURA, OUTLOOK 2009-2010 Saturn VUE 2010 Saturn SKY Attention: This bulletin does not apply to GMODC dealers. Supercede: This bulletin is being revised to add part numbers. Please discard Corporate Bulletin Number 09-00-89-025 (Section 00 - General Information). This bulletin is being published to provide information on locating service part numbers for GM Accessory, 2-Way Advanced Remote Start Systems. Dealers should consult the chart below and use the correct service part. Dealers should not use entire kit for warranty or repair work. Page 1378 Fuse: Locations Instrument Panel Fuse Block - Owners Manual INSTRUMENT PANEL FUSE BLOCK The instrument panel fuse block is located on the instrument panel near the floor on the passenger side of the vehicle. Remove the panel cover to access the fuse block, then remove the fuse block cover to access the fuses. The vehicle might not have all the fuses and features listed. 6T30/6T40/6T45 - Automatic Transmission Fluid - A/T: Testing and Inspection 6T30/6T40/6T45 - Automatic Transmission Transmission Fluid Level and Condition Check This procedure checks both the transmission fluid level, as well as the condition of the fluid itself. Caution: Use Dexron VI transmission fluid only. Failure to use the proper fluid may result in transmission internal damage. Note: Ensure the transmission has enough fluid in it to safely start the vehicle without damaging the transmission. With the vehicle off and the transmission fluid temperature at approximately 20-25°C (68-77°F) there must be at least enough fluid to drain out of the fluid level hole. This will ensure that there is enough fluid in the sump to fill the components once the vehicle is started. Non Dipstick Level Checking Procedure 1. Start the engine. 2. Depress the brake pedal and move the shift lever through each gear range, pausing for about 3 seconds in each range. Then move the shift lever back to PARK (P). 3. Allow the engine to idle 500-800 rpm for at least 3 minutes to allow any fluid foaming to dissipate and the fluid level to stabilize. Release the brake pedal. Note: If the TFT reading is not at the required temperature, allow the vehicle to cool, or operate the vehicle until the appropriate TFT is reached. If the fluid temperature is below the specified range, perform the following procedure to raise the fluid temperature to the specification. Drive the vehicle in second gear until the fluid temperature is at the specified temperature. 4. Keep the engine running and observe the transmission fluid temperature (TFT) using the Driver Information Center or a scan tool. Caution: The transmission fluid level must be checked when the transmission fluid temperature (TFT) is at 85-95°C (185-203°F). If the TFT is not at this temperature, operate the vehicle or allow the fluid to cool as required. Setting the fluid level with a TFT outside this temperature will result in either an under or over-filled transmission. TFT 95°C under-filled, TFT 85°C over-filled. An under-filled transmission will cause premature component wear or damage. An over-filled transmission will cause fluid to discharge out the vent tube, fluid foaming, or pump cavitation. 5. Raise the vehicle on a hoist. The vehicle must be level, with the engine running and the shift lever in the PARK range. 6. While the vehicle is idling, remove the oil level set plug. Allow any fluid to drain. Oil Level Plug (1) * If the fluid is flowing as a steady stream, wait until the fluid begins to drip. * If no fluid comes out, add fluid until fluid drips out. Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass airflow (MAF)/intake air temperature (IAT) sensor. 2. Loosen the air cleaner outlet duct clamp at the air cleaner assembly. 3. Remove the air cleaner outlet duct from the air cleaner assembly. 4. Disengage the air cleaner cover latches (1). 5. Open the air cleaner cover. 6. Remove and discard the air filter assembly. Installation Procedure Engine/Transmission - Aftermarket Calibrations Engine Control Module: All Technical Service Bulletins Engine/Transmission - Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 3811 Locations Central Control Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 5212 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 3822 Torque Converter Clutch Solenoid: Diagrams Component Connector End Views Torque Converter Clutch (TCC) Pulse Width Modulation (PWM) Solenoid Valve (ME7 or MN5) Interior - Gap At Rear Edge Of Shifter Trim Plate Shifter A/T: Customer Interest Interior - Gap At Rear Edge Of Shifter Trim Plate TECHNICAL Bulletin No.: 08-08-49-012B Date: September 21, 2009 Subject: Gap at Rear Edge of Front Floor Console Shifter Trim Plate (Align Mounting Tab) Models: 2008-2010 Chevrolet Malibu Supercede: This bulletin is being revised to add the 2010 model year and to update the Correction information. Please discard Corporate Bulletin Number 08-08-49-012A (Section 08 - Body and Accessories). Condition Some customers may comment on a gap at the rear edge of the floor console shifter trim plate. Cause This condition may be caused by the front floor console accessory trim plate rear clips not fully engaging with the clip slots in the console base. Correction Use the following steps to remove the front floor console accessory trim plate and inspect the trim plate clip towers, clips and the console clip slots for damage. If no damage is found, reinstall the trim plate as described in the procedure. 1. Set the parking brake. 2. Turn the ignition key to the ON position with the engine off (the engine should not be running). 3. Depress the brake pedal and place the shifter into the neutral ("N") position. Note Release the shifter boot from the shifter knob by pulling the boot retainer down in order to gain access to the shift knob front retaining screw. 4. Remove the shift control knob. Refer to Floor Shift Control Knob Replacement in SI. 5. Remove the front floor console trim plate. Refer to Front Floor Console Accessory Trim Plate Replacement in SI. 6. Inspect the underside of the shifter console trim plate for the four white attaching clips and their rib structures. - Inspect all of the shifter plate attachments, including the two small forward tabs. If none of the attachments are damaged and the shifter plate forward tip up bin lid functions properly, DO NOT REPLACE the shifter trim plate. - If any of the four attaching clips are damaged or bent, the console shifter trim plate may need to be replaced. 7. Remove the left and right console side extension panels to provide access to the clip slots in the console base from below. Refer to Front Floor Console Extension Panel Replacement in SI. 8. Position the front floor console accessory trim plate for installation. Refer to Front Floor Console Accessory Trim Plate Replacement in SI. Page 3232 Camshaft Position (CMP) Actuator Solenoid Valve - Intake (LAT) Camshaft Position (CMP) Actuator Solenoid Valve - Intake (LE5 or LE9) Page 7377 Disclaimer Page 5375 For vehicles repaired under warranty, use the table. Disclaimer Page 10030 Page 5855 6. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals on to the bare wire using the J38125-7 crimp tool, jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 7. Position the wire seal to the terminal and crimp the seal and insulation using the J-38125-6 crimp tool, jaw 1 (1). The completed terminal and seal should appear as shown above (body harness connector shown). Note Avoid getting solder on the terminal end or overheating the terminal. Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. 8. Solder all four terminals at the wire crimp. 9. Slide the two body harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Manual Transmission - M/T Operating Characteristics Manual Transmission/Transaxle: Technical Service Bulletins Manual Transmission - M/T Operating Characteristics INFORMATION Bulletin No.: 03-07-29-004G Date: December 15, 2010 Subject: Manual Transmission Operating Characteristics Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2009 and Prior Chevrolet and GMC Medium Duty Trucks 2006-2010 HUMMER H3 with Manual Transmission Supercede: This bulletin is being revised to add the 2011 model year and to add Cold Operation information. Please discard Corporate Bulletin Number 03-07-29-004F (Section 07 Transmission/Transaxle). Important Even though this bulletin attempts to cover operating characteristics of manual transmissions, it cannot be all inclusive. Be sure to compare any questionable concerns to a similar vehicle and if possible, with similar mileage. Even though many of the conditions are described as characteristics and may not be durability issues, GM may attempt to improve specific issues for customer satisfaction. The purpose of this bulletin is to assist in identifying characteristics of manual transmissions that repair attempts will not change. The following are explanations and examples of conditions that will generally occur in all manual transmissions. All noises will vary between transmissions due to build variation, type of transmission (usually the more heavy duty, the more noise), type of flywheel and clutch, level of insulation, etc. Basic Information Many transmission noises are created by the firing pulses of the engine. Each firing pulse creates a sudden change in angular acceleration at the crankshaft. These changes in speed can be reduced with clutch damper springs and dual mass flywheels. However, some speed variation will make it through to the transmission. This can create noise as the various gears will accel and decel against each other because of required clearances. Cold Operation Manual transmission operation will be affected by temperature because the transmission fluid will be thicker when cold. The thicker fluid will increase the amount of force needed to shift the transmission when cold. The likelihood of gear clash will also increase due to the greater time needed for the synchronizer assembly to perform its function. Therefore when the transmission is cold, or before it has reached operating temperature, quick, hard shifts should be avoided to prevent damage to the transmission. Gear Rattle Rattling or grinding (not to be confused with a missed shift type of grinding, also described as a combustion knock type of noise) type noises usually occur while operating the engine at low RPMs (lugging the engine). This can occur while accelerating from a stop (for example, a Corvette) or while operating at low RPMs while under a load (for example, Kodiak in a lower gear and at low engine speed). Vehicles equipped with a dual-mass flywheel (for example, a 3500 HD Sierra with the 6-speed manual and Duramax(R)) will have reduced noise levels as compared to vehicles without (for example, a 4500 Kodiak with the 6-speed manual and Duramax(R)). However, dual-mass flywheels do not eliminate all noise. Neutral Rattle There are often concerns of rattle while idling in neutral with the clutch engaged. This is related to the changes in angular acceleration described earlier. This is a light rattle, and once again, vehicles with dual mass flywheels will have reduced noise. If the engine is shut off while idling in neutral with the clutch engaged, the sudden stop of the engine will create a rapid change in angular acceleration that even dual mass flywheels cannot compensate. Because of the mass of all the components, this will create a noise. This type of noise should not be heard if the clutch is released (pedal pushed to the floor). Backlash Backlash noise is created when changing engine or driveline loading. This can occur when accelerating from a stop, coming to a stop, or applying and releasing the throttle (loading and unloading the driveline). This will vary based on vehicle type, build variations, driver input, vehicle loading, etc. and is created from the necessary clearance between all of the mating gears in the transmission, axle(s) and transfer case (if equipped). Page 2512 Transmission Position Switch/Sensor: Service and Repair Park/Neutral Position Switch Replacement Special Tools J 41545 Park/Neutral Switch Aligner Removal Procedure 1. Apply the parking brake and place the control assembly in Neutral. The transaxle manual shaft must be in the Neutral position prior to installing the range switch. 2. Remove the shift control cable from the transaxle range switch lever. 3. Disconnect the electrical connectors from the transaxle range switch. Warning Page 9162 Note: Always use care when removing a terminal position assurance (TPA) in order to avoid damaging it. 7. Remove the TPA by inserting a small flat-blade tool into the locking tabs on both sides of the TPA. Gently pry the TPA out of the connector. 8. Remove the nose piece by inserting a small flat-blade tool into the locking tabs on both sides of the nose piece. Gently pry the nose piece out of the connector. Page 3538 Ignition Coil 6 (LY7) Page 7008 Steering Gear: Service and Repair Steering Gear Replacement Steering Gear Replacement Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become UN-centered and cause possible damage to the SIR coil. If you think the SIR coil has became UN-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. Turn the front wheels to the straight ahead position and secure the steering wheel from moving. 2. Place drain pans under the vehicle. 3. Remove as much power steering fluid from the power steering fluid reservoir as possible. 4. Disconnect the steering linkage outer tie rods from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 5. Disconnect the intermediate steering shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement (See: Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 6. Loosen the rear transmission mount bracket bolt. 7. Disconnect the heated oxygen sensor (HO2S) electrical connector and unclip the connector from the rear transmission mount bracket. Page 9464 Page 6802 Alignment: Specifications Wheel Alignment Specifications Wheel Alignment Specifications Page 8188 Page 7071 11. Remove the upper shock absorber mounting bolts (1). 12. Remove the mounting bolts for the support. 13. With the aide of an assistant, lower the support. 14. Remove the support from the transmission jack stand. Page 2368 * Evaporative emission (EVAP) system losses Should this vehicles on-board diagnostic system (ECM) detect a condition that could result in excessive emissions, the ECM turns ON the malfunction indicator lamp (MIL) and stores a DTC that is associated with the condition. Aftermarket (Add-On) Electrical And Vacuum Equipment Caution: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or systems. Caution: Connect any add-on electrically operated equipment to the vehicle's electrical system at the battery (power and ground) in order to prevent damage to the vehicle. Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicles electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment. Add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include equipment not connected to the vehicle electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain condition is to eliminate all of the aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, the problem may be diagnosed in the normal manner. Electrostatic Discharge (ESD) Damage Note: In order to prevent possible electrostatic discharge damage to the engine control module (ECM), DO NOT touch the connector pins on the ECM. The electronic components that are used in the control systems are often designed to carry very low voltage. The electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 V of static electricity can cause damage to some electronic components. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore, it is important to use care when handling and testing electronic components. Emissions Control Information Label The underhood Vehicle Emissions Control Information Label contains important emission specifications and setting procedures. In the upper right corner is the exhaust emission information. This identifies the year, the manufacturing division of the engine, the displacement of the engine in liters, the class of the vehicle, and type of fuel metering system. There is also an illustrated emission components and vacuum hose schematic. This label is located in the engine compartment of every General Motors vehicle. If the label has been removed, it can be ordered from GM service parts operations (GMSPO). Underhood Inspection Note: This inspection is very important and must be done carefully and thoroughly. Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a condition without further steps. Use the following guidelines when performing an inspection: * Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects. * Inspect any hoses that are difficult to see. * Inspect all of the wires in the engine compartment for the following conditions: - Burned or chafed spots - Pinched wires - Contact with sharp edges - Contact with hot exhaust manifolds Page 6078 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 777 Front and Right Side of the Engine Components (LY7) 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 1797 Caution: Do not damage the cylinder block surface. Damage to the cylinder block surface can cause engine failure. 12. Remove EN 45680-881 fixture, EN 45680-882 cylinder bore sleeve puller, and the cylinder bore sleeve from the engine block. 13. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block. Installation Procedure Caution: Do not use assembly aids or lubricants on the cylinder bore sleeve or the cylinder bore block when installing a new cylinder bore sleeve, or engine damage will occur. These items will not aid in the installation of the new cylinder bore sleeve. Caution: Do not chill or heat the cylinder bore sleeve or the cylinder block when removing or installing a new cylinder bore sleeve. Chilling or heating the cylinder bore sleeve or the cylinder block will cause engine damage and will not aid the removal or installation of the new cylinder bore sleeve. 1. Place the NEW cylinder bore sleeve onto the cylinder block. 2. Install EN 45680-881 fixture and EN 45680-883 cylinder bore sleeve installer assembly over the cylinder bore sleeve and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve. Page 8012 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 10068 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 1342 Refrigerant Oil: Fluid Type Specifications PAG Oil GM P/N 12378526 for United States PAG Oil GM P/N 88900060 for Canada A/T Controls - Downshift Hesitation/Delayed Shifting Control Module: Customer Interest A/T Controls - Downshift Hesitation/Delayed Shifting TECHNICAL Bulletin No.: 09-07-30-016A Date: November 25, 2009 Subject: Transmission Hesitation, Delayed Shifting, Shifting at Wrong Time (Reprogram TCM) Models: 2010 Buick Enclave 2010 Chevrolet Equinox, Traverse 2010 GMC Acadia, Terrain 2010 Saturn OUTLOOK Equipped with 6T40/45 (RPOs MH7, MHC) or 6T70/75 (RPOs MH2, MH4, MY9, MH6) Automatic Transmission 2010 Buick LaCrosse Equipped with 3.0L (RPO LF1) Engine and 6T70 (RPOs MH2, MH4) Automatic Transmission 2010 Chevrolet Malibu 2010 Pontiac G6 2010 Saturn AURA Equipped with 6T40 (RPO MH8) Automatic Transmission All Vehicles Built Prior to the Following VIN Breakpoints: Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 09-07-30-016 (07- Transmission/Transaxle). Condition Some customers may comment on transmission downshift hesitation, delayed shifting and shifting at the wrong time. Correction A revised transmission calibration has been developed to address these issues. Reprogram the transmission control module (TCM) with updated calibration files using the TIS2WEB Service Programming System (SPS) application. Select SEQ Programming Sequence ECM/TCM from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Locations Air Door Actuator / Motor: Locations Instrument Panel/Center Console Component Views Behind Right Side and Center of the Instrument Panel Components 1 - Mode Actuator 2 - Air Temperature Sensor - Upper (C68) 3 - Air Temperature Actuator 4 Recirculation Actuator 5 - Air Temperature Sensor - Lower (C68) Emissions - EVAP Damage Prevention On Vehicle Hoist Vehicle Lifting: Technical Service Bulletins Emissions - EVAP Damage Prevention On Vehicle Hoist INFORMATION Bulletin No.: 05-06-04-004E Date: May 29, 2009 Subject: Information to Avoid Damaging EVAP Canister and Setting DTCs P0442/P0455 When Hoisting Vehicle Models: 2004-2007 Chevrolet Malibu MAXX 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn AURA .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 05-06-04-004D (Section 06 Engine). .............................................................................................................................................................. .................................................................................. A review of warranty repair orders and parts returned to GM for analysis suggests that EVAP canisters are being damaged when the vehicle is being put up on a hoist for service. Incorrect placement of the hoist pads may cause a crack/leak in the EVAP canister plastic and eventually set one or both of the following DTCs: - DTC P0442 - small EVAP leak detected - DTC P0455 - large EVAP leak detected To avoid this situation, particularly when using the type of hoist where the arms swing in and the pick up pads swivel, be sure of the placement of the pick up pads. If the pick up pads are not positioned correctly to the underbody pick up areas, this type of damage may occur. Lifting Points (2008 Chevrolet Malibu Shown, Other Vehicles Similar) Lifting Pad Body Seam - DO NOT Lift Here EVAP Canister - DO NOT Lift Here For additional information and detail, refer to Lifting and Jacking the Vehicle in SI. Page 3601 * Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. * Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Page 6854 If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 10. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 11. Install the connector to the sensor. 12. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A raised rotor flange cuff (4) * An alignment mark (3) for installation 13. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the raised rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 14. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 15. Install the connector to the sensor. 16. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (2) for the centering pin-Note the location of the pin hole. * A flush rotor flange cuff (4) * An alignment mark (3) for installation 17. From the technicians point of view, the BACK of the sensor will have an alignment tab (1) for installation. This sensor does not have double D flats. Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 18. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. Locations Pedal Positioning Sensor: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Lower Left Side of the Instrument Panel Components (1 of 2) Page 2809 Page 8176 Page 6818 3. If the strut has not been modified previously, perform the following steps before continuing with the wheel alignment: 1. Disconnect the strut from the knuckle. Refer to Strut Assembly Replacement (See: Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Strut/Strut Assembly Replacement). 2. File the lower hole until the outer flange slot matches the inner flange slot. 3. Connect the strut to the knuckle. Refer to Strut Assembly Replacement (See: Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Strut/Strut Assembly Replacement). 4. Adjust the camber to specification by moving the top of the wheel in or out. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Page 3009 Page 2748 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 975 Steering Angle Sensor: Service and Repair Steering Wheel Position Sensor Centering Steering Wheel Position Sensor Centering Removal Procedure Caution: With wheels of the vehicle facing straight ahead, secure the steering wheel utilizing steering column anti-rotation pin, steering column lock, or a strap to prevent rotation. Locking of the steering column will prevent damage and a possible malfunction of the SIR system. The steering wheel must be secured in position before disconnecting the following components: * The steering column * The intermediate shaft(s) * The steering gear After disconnecting these components, do not rotate the steering wheel or move the front tires and wheels. Failure to follow this procedure may cause the SIR coil assembly to become UN-centered and cause possible damage to the SIR coil. If you think the SIR coil has became UN-centered, refer to your specific SIR coil's centering procedure to re-center SIR Coil. 1. With the wheels of the vehicle in the straight ahead position, secure the steering wheel or the steering column with a steering column anti-rotation pin, a steering column lock, or a strap, as applicable, in order to prevent rotation. Note: Identify the type of steering wheel position sensor from the illustrations shown BEFORE removing the sensor from the steering column. Once you have identified the steering wheel position sensor, follow the instructions listed in the removal procedure. 2. Verify the type of steering wheel position sensor. 3. From the technicians point of view of the FRONT of the sensor (1), the connector will be on the right. Note: If you are reusing the existing sensor, you do not have to align the sensor before removal. Centering is not necessary in order to install the old sensor. 4. Remove the connector from the sensor. 5. Remove the sensor from the adapter and bearing assembly. 6. To install the sensor, proceed to step 1 in the installation procedure. 7. From the technicians point of view, the FRONT of the sensor will have: * A foam ring (2) * A pin hole (1) for the centering the pin-Note the location of the pin hole. Brake Pedal Position Sensor Calibration Pedal Positioning Sensor: Service and Repair Brake Pedal Position Sensor Calibration Brake Pedal Position Sensor Calibration Calibration Criteria Important: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor (BPPS) calibration must be repeated. Brake pedal position sensor calibration must be performed after the brake pedal position sensor or body control module (BCM) have been serviced. The calibration procedure will set the brake pedal position sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via the GMLAN communication bus. Calibration Procedure 1. Apply the parking brake. 2. Place the transmission in the PARK position. 3. Install a scan tool. 4. Clear all BCM DTCs before proceeding. 5. Navigate to the Vehicle Control Systems menu. 6. Select Module Setup menu item. 7. Select BCM menu item. 8. Select the BPP Sensor Calibration procedure and follow the directions displayed on the screen. Page 9429 Rear Seat Back Cushion Support Replacement Rear Seat Back Cushion Support Replacement Page 7098 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 5. Install the (3) trailing arm to knuckle bolts (1) and tighten to 180 Nm (133 lb ft). 6. Install the lower shock to knuckle bolt. Refer to Shock Absorber Replacement (See: Suspension Strut / Shock Absorber/Service and Repair/Rear Suspension Shock Absorber/Shock Absorber Replacement). 7. Install the wheel bearing/hub assembly. Refer to Rear Wheel Bearing and Hub Replacement (See: Wheel Bearing/Service and Repair/Rear Suspension). 8. Install the park brake cable (1) on the trailing arm. 9. Install the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 10. Lower the vehicle. 11. Perform a vehicle wheel alignment. Refer to Wheel Alignment Measurement (See: Alignment/Service and Repair/Wheel Alignment Measurement). Page 8990 Page 4268 Transmission Rear Mount Replacement Transmission Rear Mount Replacement Page 8668 Body Control Module (BCM) X4 Steering - Front End Clunk/Rattle/Knock On Bumps Stabilizer Link: Customer Interest Steering - Front End Clunk/Rattle/Knock On Bumps TECHNICAL Bulletin No.: 06-02-32-007G Date: April 05, 2010 Subject: Clunk, Knock or Rattle Noise From Front of Vehicle While Driving or Turning Over Bumps at Low Speeds (Diagnose Noise and Perform Outlined Repair) Models: 2004-2006 Chevrolet Malibu Maxx 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn Aura Supercede: This bulletin is being revised to update the Parts Information for the bolt. Please discard Corporate Bulletin Number 06-02-32-007F (Section 02 - Steering). Condition 1 Some customers may comment on a clunk noise heard and felt in the steering wheel while driving at slow speeds and turning. The clunk noise may appear to be directly in front of the driver. Hitting a bump while turning can produce the clunk noise. Sometimes the noise may be duplicated when the vehicle is sitting still and the steering wheel is turned 90 degrees in either direction before initially centering the steering wheel. Cause 1 The clunk noise may be caused by a slip/stick condition between the inner and outer components of the intermediate shaft. Important Revised design intermediate shafts went into production in the 2009 model year and are the only design currently available through GMSPO since approximately September 2008. Since any model year vehicle could have had a second design shaft installed, it is critical to identify it before proceeding. The revised design intermediate shafts will NOT tolerate any type of lubricant per the following instructions. Adding lube to the second design shafts will cause a clunk noise in a very short period of time. Use the following pictures to identify which design of shaft you are servicing. Electric Assist Power Steering First Design - Bare Steel Tube (Lube OK) Page 8212 Page 6311 Generator Battery 3 (+) (HP7) Generator Battery Assembly X1 (HP7) Generator Battery Assembly X2 (HP7) Generator Battery Assembly X3 (HP7) Generator Battery Disconnect Control Module X1 (LAT) Page 5137 Page 7523 3. Install the compressor clutch coil snap ring using the J 6083. 4. Install the compressor pulley to the compressor. Page 1530 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Locations Transmission Mode Switch: Locations Powertrain Component Views Automatic Transmission Electronic Components (MH2) 1 - Control Solenoid Valve Assembly 2 - Automatic Transmission Internal Mode Switch (IMS) 3 Automatic Transmission Output Shaft Speed (OSS) Sensor 4 - Automatic Transmission Input Shaft Speed (ISS) Sensor Page 3800 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Front of the Transmission Components (MH2 or MH8) Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Charge .............................................................................................................................. ............................................................ 0.5 kg (1.1 lb) Page 333 Page 2546 Note: Inspect the CMP sensor for damage, replace as necessary. 1. Lubricate the CMP sensor O-ring seal with clean engine oil. 2. Install the CMP sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the CMP sensor bolt and tighten to 10 Nm (89 lb in). 4. Connect the engine wiring harness electrical connector (7) to the intake CMP sensor (6). 5. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). Page 1593 * Uneven braking action * Steering lead * Imprecise vehicle handling Page 6016 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Page 8183 Page 2754 Engine Control Module (ECM) X1 (LY7) Page 4355 Continuously Variable Transmission/Transaxle: Technical Service Bulletins Vehicle - Engine Crankcase and Subsystems Flushing Info. INFORMATION Bulletin No.: 04-06-01-029E Date: April 29, 2010 Subject: Unnecessary Flushing Services, Additive Recommendations and Proper Utilization of GM Simplified Maintenance Schedule to Enhance Customer Service Experience Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and add information about the proper transmission flush procedure. Please discard Corporate Bulletin Number 04-06-01-029D (Section 06 - Engine/Propulsion System). An Overview of Proper Vehicle Service General Motors is aware that some companies are marketing tools and equipment to support a subsystem flushing procedures. These dedicated machines are in addition to many engine oil, cooling system, fuel system, A/C, transmission flush and steering system additives available to the consumer. GM Vehicles under normal usage do not require any additional procedures or additives beyond what is advised under the former Vehicle Maintenance Schedules or the current Simplified Maintenance Schedules. Do not confuse machines available from Kent-Moore/SPX that are designed to aid and accelerate the process of fluid changing with these flushing machines. Engine Crankcase Flushing General Motors Corporation does not endorse or recommend engine crankcase flushing for any of its gasoline engines. Analysis of some of the aftermarket materials used for crankcase flushing indicate incompatibility with GM engine components and the potential for damage to some engine seals and bearings. Damage to engine components resulting from crankcase flushing IS NOT COVERED under the terms of the New Vehicle Warranty. GM Authorized Service Information: Detailed, Descriptive, and Complete If a specific model vehicle or powertrain need is identified, GM will issue an Authorized Service Document containing a procedure and, if required, provide, make available, or require the specific use of a machine, tool or chemical to accomplish proper vehicle servicing. An example of this is fuel injector cleaning. Due to variation in fuel quality in different areas of the country, GM has recognized the need for fuel injector cleaning methods on some engines, though under normal circumstances, this service is not part of the maintenance requirements. GM has published several gasoline fuel injector cleaning bulletins that fully outline the methods to be used in conjunction with GM Part Numbered solutions to accomplish proper and safe cleaning of the fuel injectors with preventative maintenance suggestions to maintain optimum performance. You may refer to Corporate Bulletin Numbers 03-06-04-030 and 04-06-04-051 for additional information on this subject. Subsystem Flushing Flushing of A/C lines, radiators, transmission coolers, and power steering systems are recognized practices to be performed after catastrophic failures or extreme corrosion when encountered in radiators. For acceptable A/C flushing concerns, refer to Corporate Bulletin Number 01-01-38-006. This practice is NOT required or recommended for normal service operations. The use of external transmission fluid exchange or flush machines is NOT recommended for the automatic or manual transmission. Use of external machines to replace the fluid may affect the operation or durability of the transmission. Transmission fluid should only be replaced by draining and refilling following directions in SI. Refer to Automatic/Manual Transmission Fluid and Filter Replacement. Approved Transmission Flushing Tool (Transmission Cooler Only) The Automatic Transmission Oil Cooler Flush and Flow Test Tool is recommended for GM vehicles. Refer to Transmission Fluid Cooler Flushing and Flow Test in SI using the J 45096. Service Is Important to You and Your Customer General Motors takes great pride in offering our dealerships and customers high quality vehicles that require extremely low maintenance over the life of the vehicle. This low cost of ownership builds repeat sales and offers our customers measurable economy of operation against competing vehicles. Page 783 Page 4396 17. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 18. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. * The inner and outer race assemblies * The CV joint cage * The chrome alloy balls 19. Dry all the parts. 20. Check the CV joint assembly for the following items: * Unusual wear * Cracks * Damage 21. Replace any damaged parts. 22. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Installation Procedure Page 7012 9. Tighten the rear transmission mount bracket bolt and tighten to 90 Nm (66 lb ft). 10. Connect the intermediate steering shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement (See: Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 11. Connect the steering linkage outer tie rods to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement (See: Tie Rod/Service and Repair/Steering Linkage Outer Tie Rod Replacement). 12. Fill and bleed the power steering system. Refer to Power Steering System Bleeding (See: Power Steering/Power Steering Bleeding/Service and Repair). 13. Clean any excess power steering fluid from the vehicle. 14. Remove the drain pans. 15. Measure and adjust the front toe. Refer to Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment (See: Alignment/Service and Repair/Wheel Alignment - Steering Wheel Angle and/or Front Toe Adjustment). Page 8662 Body Control Module: Locations Instrument Panel/Center Console Component Views Behind the Instrument Panel Components 1 - Vehicle Communications Interface Module (VCIM) (UE1) 2 - Inflatable Restraint I/P Module 3 Adjustable Pedal Position Motor (JF4) 4 - Theft Deterrent Module (TDM) 5 - Adjustable Pedal Module (JF4) 6 - Brake Pedal Position (BPP) Sensor 7 - Body Control Module (BCM) 8 - Adjustable Pedal Position Sensor (JF4) 9 - Wireless Communication Interface Antenna Bluetooth (UPF) Page 1477 Page 9592 Page 9037 Center Pillar Lower Garnish Molding Replacement Center Pillar Lower Garnish Molding Replacement Diagram Information and Instructions Keyless Entry Transmitter: Diagram Information and Instructions Master Electrical Schematic Icons Master Electrical Schematic Icons Electrical Schematic Symbols Electrical Schematic Symbols Body - Vehicle Glass Distortion Information Windshield: All Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Page 6787 For vehicles repaired under warranty, use the table. Disclaimer Page 8375 ‹› If the tester indicates that one or more of the buttons does not respond, replace the GDO. 5. Instruct the customer to program the GDO. Refer to the vehicle owners manual. A possible rolling code or incompatibility with the GDO receiver will prevent programming. Repair Instructions Perform the Diagnostic Repair Verification (See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests and Procedures) after completing the diagnostic procedure. Control Module References (See: Testing and Inspection/Programming and Relearning) for GDO replacement, setup, and programming Page 4791 Brake Rotor/Disc: Testing and Inspection Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Brake Rotor Assembled Lateral Runout Correction - On Vehicle Lathe Special Tools CH-45101-100 - Conical Brake Rotor Washers For equivalent regional tools, refer to Special Tools (See: Tools and Equipment). Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). Note: * Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement (See: Brake Rotor Thickness Variation Measurement). * Brake rotor assembled LRO exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement (See: Brake Rotor Thickness Measurement). 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish. 2. Using moderate pressure, apply the non-directional finish: * If the lathe is equipped with a non-directional finishing tool, apply the finish with 120-grit aluminum oxide sandpaper. * If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150-grit aluminum oxide sandpaper. 3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner. 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout Measurement (See: Brake Rotor Assembled Lateral Runout Measurement). 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout Correction (See: Brake Rotor Assembled Lateral Runout Correction). 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the CH-45101-100 - Conical Brake Rotor Washers and the lug nuts. Page 9940 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 6969 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Page 6297 Fuel Injector 1 (LZ4 or LZE) Fuel Injector 2 (LAT or LE5 or LE9) Page 3958 4. Start the engine. Warm up the transaxle, and check for leaks. 5. Inspect for proper fluid level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Symptom Related Diagnostic Procedures/4T45-E - Automatic Transmission/Transmission Fluid Level and Condition Check). Page 5915 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 8921 2. Align the split of the bushing to the front of the frame. 3. Using J-45725 install the bushing until the entire radius of the bushing is halfway recessed in the cradle. Page 9929 * Kostel has an "LK" with a circle around it. These connector are usually used as a transmissions connection. * Most Molex connectors will have the Molex logo on the dresscover of the connector. In some cases the connectors may have MX followed by another letter. The third letter indicates where the connector was made. A connector with MXD is a Molex connector made in Detroit. Page 613 Wheel Speed Sensor (WSS) - Right Front Wheel Speed Sensor (WSS) - Right Rear Locations Oxygen Sensor: Locations Powertrain Component Views Lower Front and Rear of the Engine Components (LAT or LE5 or LE9) 1 - Knock Sensor (KS) 2 - Heated Oxygen Sensor (HO2S) 1 3 - Heated Oxygen Sensor (HO2S) 2 4 - Engine Coolant Temperature (ECT) Sensor Lower Front and Rear of the Engine Components (LY7) Page 10808 Page 4016 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid Valve Replacement Removal Procedure Important: Retainer clips hold in each of the valve line-ups. Use a small screwdriver in order to remove the retainer clips. Be careful not to score the valve body when removing the retainer clips and valves. Before removing the valve line-ups, inspect each valve line-up for freedom of movement. 1. Remove the transmission side cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/4T45-E - Automatic Transmission/Control Valve Body Cover Replacement) 2. Remove the Pressure Control Solenoid (PCS) retainer clip (304), the PCS with two O-rings and screen (312, 309, 310), the torque signal regulator valve (309), and the torque signal regulator spring (308). Installation Procedure 1. Install the torque signal regulator spring (308), the torque signal regulator valve (309), the Pressure Control Solenoid (PCS) with two O-rings and screen (312, 309, 310) and the PCS retainer clip (304). 2. Install the transmission side cover. Refer to Control Valve Body Cover Replacement (See: Valve Body/Service and Repair/4T45-E - Automatic Transmission/Control Valve Body Cover Replacement). Important: It is recommended that transmission adaptive pressure (TAP) information be reset. Resetting the TAP values using a scan tool will erase all learned values in all cells. As a result, The ECM, PCM or TCM will need to relearn TAP values. Transmission performance may be affected as new TAP values are learned. 3. Reset the TAP values. Refer to Transmission Adaptive Functions (See: Description and Operation/4T45-E - Automatic Transmission/Transmission Adaptive Functions). Page 9524 6. Release the rear lower half of the wire dress cover. 7. Release the tabs that are holding the wire dress cover to the connector body. 8. Remove the nose piece by inserting a small flat-blade tool into the slots on both ends of the connector body. Gently pry the nose piece out of the connector. J 38125-216 can also be used to remove the nose piece. Page 421 Electric Power Steering (EPS) Module X3 (without NVH) Page 801 Crankshaft Position Sensor: Diagrams Component Connector End Views Crankshaft Position (CKP) Sensor (LAT or LE5 or LE9) Crankshaft Position (CKP) Sensor (LY7) Page 2864 4. Release the lower wire dress cover locking tab. 5. Release the upper wire dress cover locking tab. 6. Once the locks are unlocked, lift the dress cover off. Page 7745 Ambient Temperature Sensor / Switch HVAC: Diagrams Component Connector End Views Ambient Air Temperature Sensor Page 6468 Ambient Light Sensor (C60) Audio Amplifier X1 (UQA) Page 6426 Sunroof Switch (CF5) Page 8140 Antenna Cable: Service and Repair Antenna Cable Replacement Antenna Cable Replacement Removal Procedure 1. Remove the headliner. Refer to Headlining Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair). 2. Remove the rear window shelf panel. Refer to Rear Window Shelf Trim Panel Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Rear Window Shelf Trim Panel Replacement). 3. Remove the antenna cable from the vehicle. Installation Procedure Page 8146 Alarm Module: Diagrams Component Connector End Views Theft Deterrent Module (TDM) Page 7096 9. Remove the upper control arm to knuckle bolt. Installation Procedure 1. Position the knuckle to the upper control arm and install the bolt and nut. Refer to Rear Axle Upper Control Arm Replacement (See: Control Arm/Service and Repair/Rear Suspension/Rear Axle Upper Control Arm Replacement) 2. Install the coil spring. Refer to Coil Spring Replacement (See: Suspension Spring ( Coil / Leaf )/Service and Repair/Rear Suspension Coil Spring/Coil Spring Replacement). Page 1769 Note: * Ensure that the alignment mark made previously on the intake camshaft actuator is still aligned properly with the mark on the timing chain. * The exhaust camshaft may need to be rotated clockwise to fully set the camshaft actuator. 1. Install the timing chain onto the exhaust camshaft actuator. 2. Align the exhaust camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft. 3. Install a NEW exhaust camshaft actuator bolt (2) until snug. Note: Ensure that the alignment mark previously on the exhaust camshaft actuator is still aligned properly with the timing chain. If the mark made previously on the intake camshaft actuator is not aligned properly, refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement (See: Timing Components/Timing Chain Tensioner/Service and Repair). 4. Remove the EN-48749 - retention tool (1) from the exhaust side of the timing chain. Note: Failure to reset the tensioner will allow the tensioner to over extend. limiting the timing chain life. 5. Reset and install the timing chain tensioner. Refer to Timing Chain Tensioner Replacement (See: Timing Components/Timing Chain Page 10029 Page 1442 Page 5655 Battery (+) X2 (LAT) Battery (-) Battery Current Sensor (HP7) Battery Current Sensor (LAT or LE5 or LY7 or LE9) Page 1650 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Page 4978 Brake Fluid Level Sensor/Switch: Diagrams Component Connector End Views Brake Fluid Level Switch Page 4508 Transmission Speed Sensor: Connector Views Component Connector End Views Automatic Transmission Input Shaft Speed (ISS) Sensor Automatic Transmission Output Shaft Speed (OSS) Sensor (MH2 or MH8) Page 5623 Window Switch - Left Rear Page 5005 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 5167 Page 6782 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Page 7414 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: * The wheel/nut has the word Metric stamped on the face. * The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. * M = Metric * 12 = Diameter in millimeters * 1.5 = Millimeters gap per thread Page 7282 If the engineer is unable to take your call, please leave the following information in a message: - Technician Name - Dealer Name and Phone Number - Complete VIN and Repair Order Number If the engineer is unable to respond within one hour, please proceed with normal diagnostics and repair based on the information found in SI. Warranty Information For vehicles repaired under engineering direction, use the table above. Disclaimer Page 3428 5. Disconnect the fuel injector wiring harness electrical (1) from the manifold absolute pressure (MAP) sensor. 6. Remove the engine wiring harness clips (1) from the fuel rail tabs (2). Page 332 Engine Control Module (ECM) X1 (LY7) Page 2093 Coolant Line/Hose: Service and Repair Engine Coolant Air Bleed Pipe Replacement Engine Coolant Air Bleed Pipe Replacement Removal Procedure 1. Remove the intake manifold cover. Refer to Fuel Injector Sight Shield Replacement (). 2. Remove the surge tank inlet hose. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement (See: Coolant Reservoir/Service and Repair/Radiator Surge Tank Inlet Hose/Pipe Replacement). 3. Remove the fuel feed pipe line nut (2). 4. Remove the fuel feed line clip from the stud and reposition the fuel feed line. 5. Remove the coolant air bleed hose/pipe bolt (3) from the upper intake manifold. 6. Reposition the coolant air bleed hose clamp (2) at the water outlet. 7. Remove the coolant air bleed hose from the water outlet. Page 2801 Exploded Views Transmission Speed Sensor: Exploded Views Disassembled Views Disassembled Views Case and Associated Parts (1 of 3) 1 - Side Cover (Structural) 2 - Axle Oil Seal 3 - Side Cover Bolt 4 - Side Cover Stud 5 - Side Cover Gasket 6 - Side Cover Oil Level Control Gasket 7 - Thrust Washer (Side Cover to Driven Sprocket) 8 - Oil Pump Bolt 9 - Oil Pump Bolt 10 - Transaxle Oil Pump Assembly 11 - Transaxle Wiring Assembly 12 - TFP Manual Valve Position Switch Assembly Bolt 13 - TFP Manual Valve Position Switch Assembly 14 - Wiring Harness Pass-Through Connector O-Ring Seal 15 - Wiring Harness Bracket Bolt/Input Speed Sensor Bolt 51 - Transaxle Case 52 - Vent Cap 55 - Torque Converter Assembly 61 - Output Speed Sensor Stud 62 - Output Shaft Speed Sensor 63 - O-Ring Seal (Output Speed Sensor) 64 - Band Anchor Pin (Lo/Reverse) 65 - Oil Level Control Plug 81 - Tube Assembly Bolt/Bottom Pan Bolt 84 - Transaxle Oil Filter Seal Page 9561 3. Remove the dress cover by using a flat-blade tool to release the connector locking tabs and pulling off the dress cover. 4. Relieve the tension on the nose piece retainers by inserting J 38125-12A into the single retainer slot on the end of the nose piece and gently prying out the locking tab. Repeat the process for both of the nose piece locking tabs on the opposite side of the nose piece. Page 2547 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Exhaust Camshaft Position Sensor Replacement - Exhaust Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (5) from the exhaust camshaft position (CMP) sensor (4). 3. Remove the CMP sensor bolt. (Intake CMP shown, exhaust CMP similar). 4. Remove the CMP sensor. Installation Procedure Page 6326 Heated Seat Control Module - Passenger X1 (KA1) Page 7916 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Attach Passenger Side Harness to Seat 1. Insert the connector retainer clip into the rectangular attachment hole (1) on the passenger seat as shown in the illustration. 2. Ensure that the service loop (2) faces towards the front of the seat. 3. Insert the taped-on gray clip into the round attachment hole (3) as shown in the illustration. 4. Attach the existing black clip to the new seat suspension location (4). Reinstall Seats 1. Make the connections between the seat airbag harness and the body harness. Note Apply medium strength Loctite (blue) to bolts before installing. 2. Install both the driver and passenger seats. Refer to Front Seat Replacement - Bucket in SI. 3. Move the seat to the maximum forward position and raise the seat to its maximum height. 4. Using a flash light, locate the air bag and body wire harnesses. 5. Secure the air bag harness (2) to the body harness (3) using a tie strap (4) as shown in the illustration. The air bag harness (2) is secured to the body harness (3) approximately 100 mm (3.9 in) from the back of the air bag connector (1). 6. Remove excess tie strap with wire cutters. 7. Enable the SIR system. Refer to SIR Disabling and Enabling in SI. 8. Turn the ignition on and use the diagnostic tool to clear the SDM DTCs and verify that the issue has been corrected. If the code is still current, refer to the appropriate diagnostic procedure found in SI. 2008 Model Year Buick Enclave, GMC Acadia and Saturn OUTLOOK Vehicles Only Note The seat mounted side impact airbag connection to the body harness is located at the forward edge of the seat, below the plastic trim. The connectors are yellow. The body harness wires are exposed - running forward in the vehicle, down through the carpet cutout in the floor. Page 9595 Heated Oxygen and Oxygen Sensor Caution Oxygen Sensor: Service Precautions Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation. Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type. Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged. This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: * Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance. * Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. * Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire. * Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance. * Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed. Page 10517 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Page 3010 Page 635 Lower Front and Rear of the Engine Components (LY7) 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Page 4894 2. Install the BPMV to the bracket (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the BPMV bolt (1) and tighten to 10 Nm (89 lb in). Page 5214 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Page 9406 Power Seat Motor: Service and Repair Front Seat Adjuster Actuator Replacement Front Seat Adjuster Actuator Replacement Page 6590 Fuse Block - Rear X3 Procedures Clockspring Assembly / Spiral Cable: Procedures Inflatable Restraint Steering Wheel Module Coil Centering Caution: The new SIR coil assembly will be centered. Improper alignment of the SIR coil assembly may damage the unit, causing an inflatable restraint malfunction. 1. Verify the following conditions before centering the supplemental inflatable restraint (SIR) steering wheel module coil: * The wheels on the vehicle are straight ahead. * The block tooth and the centering mark (1) of the steering shaft is in the 12 o'clock position. 2. If available, remove the yellow retaining tab (1) from the SIR steering wheel module coil and save the tab for reassembly. 3. Hold the SIR steering wheel module coil face up by the casing (2). 1. Slowly turn the SIR steering wheel module coil hub (3) clockwise until the coil ribbon stops. 2. Slowly rotate the SIR steering wheel module coil hub (3) counterclockwise 2.5 revolutions until the centering window (4) turns yellow. This indicates the CENTER position. Note: If the retaining tab is not available, the use of tape to secure the SIR steering wheel module coil is recommended for installation to the steering column. 4. Install the yellow retaining tab (1) to the SIR steering wheel module coil. 5. Slide the centered SIR steering wheel module coil onto the steering shaft. Page 9678 5. Ensure the TPA is fully seated. The TPA should be centered and flush with the connector body when viewed. Molex Connectors Molex Connectors Special Tools J-38125 Terminal Repair Kit Terminal Removal Procedure 1. Locate the connector position assurance (CPA) on the top of the wire dress cover. Slide the CPA forward. 2. Slide the lever lock forward while pressing down on the lever lock release tab. Page 9641 The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: * Turn ON the ignition, with the engine OFF. * Turn ON the engine. * Turn ON the circuit and/or system with a scan tool in Output Controls. * Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the Digital Multimeter (DMM). 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop Measuring Voltage Drop Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the difference in voltage potential between 2 points. 1. Set the Digital Multimeter (DMM) to the V (DC) position. 2. Connect the positive lead of the DMM to one point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors Probing Electrical Connectors Note: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Front probe Page 6588 Page 6810 Lead/Pull Description Lead/Pull Description At a constant highway speed on a typical straight road, lead/pull is the amount of effort required at the steering wheel to maintain the vehicle's straight path. Important: Vehicles will tend to lead/pull in the direction of the road slope as part of normal operation. Lead/pull is usually caused by the following factors: * Road slope * Variability in tire construction * Wheel alignment (front cross caster and camber) * Unbalanced steering gear * Electronic Power Steering (EPS) steering position and torque sensors not calibrated correctly, if equipped. Torque Steer Description Torque Steer Description A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration. The following factors may cause torque steer to be more apparent on a particular vehicle: * A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front tires for differences in the brand, the construction, or the size. If the tires appear to be similar, change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. * A large difference in the right and left front tire pressure * Left-to-right differences in the front view axle angle may cause significant steering pull in a vehicle. The pull will be to the side with the most downward sloping axle from the differential to the wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to level ground may be used as an indication of bias axle angles. The side with the higher transaxle pan (shown on the left side of the illustration) has the most downward sloping axle angle. Memory Steer Description Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander Description Page 56 Caution When performing service on or near the SIR components or the SIR wiring, the SIR system must be disabled. Failure to observe the correct procedure could cause deployment of the SIR components. Serious injury can occur. Failure to observe the correct procedure could also result in unnecessary SIR system repairs. 1. Perform the Diagnostic System Check-Vehicle. 2. Identify the DTC that is set AND review the DTC Descriptor in the corresponding diagnostic procedure. Refer to Diagnostic Trouble Code (DTC) List-Vehicle in SI. 3. Using the information from the DTC Descriptor, determine the location of the affected electrical connector. Refer to SIR Identification Views and the Master Electrical Component List in SI. 4. Turn OFF the ignition and disable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 5. BEFORE removing, INSPECT the CPA retainer at the electrical connector. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. ‹› If the CPA retainer is loose, damaged, or will not seat in the connector, replace it with a new one. Reinstall the CPA correctly by first pushing the connector body in completely, and then pushing the CPA retainer in completely. ‹› If the CPA retainer is not loose or damaged and is properly seated, proceed to Step 6. 6. Remove the CPA retainer and disconnect the electrical connector. Inspect the terminals for the following conditions: - Corrosion - Contamination - Terminal tension - Damage Important The terminals in the SIR/SRS system are made with a special plating. This plating provides the necessary contact integrity for the sensitive, low energy circuits. Use the J-38125 SIR/SRS Terminal Repair Kit for repairing SIR/SRS terminals and connectors. DO NOT substitute any other terminals for those in the repair kit. ‹› If the terminals are damaged, corrosion is observed, or have poor tension, repair or replace as necessary. Apply dielectric grease, GM P/N 12345579 (in Canada, use P/N 10953481) on the connector pins and terminals when reassembling. Refer to SIR/SRS Wiring Repairs in SI. Note The connector and connector position assurance (CPA) may seat independent of each other. Both the connector and CPA should seat with an audible and/or tactile click. The CPA isolates the shorting-bars within the connector allowing the deployment circuit to operate properly. 7. Connect the electrical connector, and install the CPA retainer. 8. Enable the supplemental inflatable restraint (SIR) system. Refer to SIR Disabling and Enabling in SI. 9. Clear the DTC with a scan tool. 10. Verify that the DTC does not reset by performing the Diagnostic Repair Verification in SI. ‹› If any DTC resets, then refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Parts Information Note If the CPA retainer P/N 54590003 (Orange CPA) cannot be located in the J-38125 SIR/SRS terminal repair kit, contact Kent Moore Tools and order P/N 54590003-PKG to obtain a package of 5. Page 1230 3. Install the thermal bypass hose to the crossover pipe. 4. Position the thermal bypass hose clamp at the crossover pipe. 5. Install the radiator inlet hose to the crossover pipe. 6. Position the radiator inlet hose clamp at the crossover pipe. Page 3706 Transmission Position Switch/Sensor: Diagrams Component Connector End Views Park/Neutral Position (PNP) Switch (ME7 or MN5) Page 4324 Assembly/Service and Repair/Wheel Drive Shaft Replacement). 17. Install the left lower control arm to the subframe and steering knuckle. Refer to Lower Control Arm Replacement (See: Steering and Suspension/Suspension/Control Arm/Service and Repair/Front Suspension). 18. Install the left front tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 19. Lower the vehicle. 20. Remove the engine support fixture. Refer to Engine Support Fixture (See: Engine, Cooling and Exhaust/Engine/Service and Repair/Removal and Replacement/Engine Support Fixture). 21. Install the PNP switch. Refer to Park/Neutral Position Switch Replacement (See: Sensors and Switches - A/T/Transmission Position Switch/Sensor/Service and Repair). 22. Install the PNP switch lever and nut. Tighten the nut to 35 Nm (26 lb ft). 23. Install the shift cable bracket. 24. Connect the shift cable to the PNP switch. Locations Oil Pressure Sender: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) Page 9577 * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J-38125 to crimp DuraSeal splice sleeve. In order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. Page 6019 4. Insert the appropriate adapter from the on the flat wire harness connector in order to test the circuit in question. Control Module/Component Voltage and Grounds Poor voltage or ground connections can cause widely varying symptoms. * Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Power Distribution Schematics (See: Diagrams/Electrical Diagrams/Power Distribution Schematics). * Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Ensure that the circuit can carry the current necessary to operate the component. Refer to Circuit Testing (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Circuit Testing) and Ground Distribution Schematics (See: Diagrams/Electrical Diagrams/Ground Distribution Schematics). Temperature Sensitivity * An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot. * Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable. * If the intermittent is related to heat, review the data for a relationship with the following: - High ambient temperatures - Underhood/engine generated heat - Circuit generated heat due to a poor connection, or high electrical load - Higher than normal load conditions, towing, etc. * If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion. - The condition only occurs on a cold start. - The condition goes away when the vehicle warms up. * Information from the customer may help to determine if the trouble follows a pattern that is temperature related. * If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions) in order to duplicate the conditions required. Electromagnetic Interference (EMI) and Electrical Noise Some electrical components/circuits are sensitive to electromagnetic interference (EMI) or other types of electrical noise. Inspect for the following conditions: * A misrouted harness that is too close to high voltage/high current devices such as secondary ignition components, motors, generator etc-These components may induce electrical noise on a circuit that could interfere with normal circuit operation. * Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch-These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating. * Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc-These accessories may lead to interference while in use, but do not fail when the accessories are not in use. Refer to Checking Aftermarket Accessories (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Checking Aftermarket Accessories). * Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode. * The generator may be allowing AC noise into the electrical system. Incorrect Control Module * There are only a few situations where reprogramming a control module is appropriate: - A new service control module is installed. - A control module from another vehicle is installed. - Revised software/calibration files have been released for this vehicle. Page 10232 Customer TPMS Information Page 3892 Page 8750 Front Door Panel: Service and Repair Front Side Door Water Deflector Replacement Front Side Door Water Deflector Replacement Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Rear Compartment Lid Weatherstrip Replacement Page 10430 Page 8795 Page 7876 Clockspring Assembly / Spiral Cable: Removal and Replacement Steering Wheel Inflatable Restraint Module Coil Replacement Page 8702 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia Bracket Replacement Rear Bumper Fascia Bracket Replacement Page 5560 Rear Compartment Lid Release Switch Rear Window Defogger Grid X1 Page 5877 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Page 5439 Engine Control Module (ECM) X1 (LE5 or LE9) Service and Repair Front Door Limiter: Service and Repair Front Side Door Check Link Replacement Service and Repair Utility Storage Compartment: Service and Repair Load Floor Rear Compartment Cover Replacement Removal Procedure Warning To help avoid personal injury, always ensure the ignition switch is in the OFF position and the ignition key has been removed prior to working on any 36V components. After the key has been removed, disconnect the negative 12V battery cable and then open the battery energy control module cover. After waiting for at least 5 minutes, measure the voltage potential using a DMM between the following: 1. 36V positive and negative battery cables 2. 36V positive battery cable and vehicle ground 3. 36V negative battery cable and vehicle ground All measured voltage levels must be below 3 volts. 1. Remove the ignition key from the ignition switch. Secure the ignition key in order to ensure that the key CANNOT be re-installed without your knowledge. 2. Disconnect the 12 volt negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Fold down both rear seat backs. 4. Carefully lift up on the load floor rear compartment cover (1) at the retaining clip (2) locations. Electrical - Intermittent MIL/DTC P2138/Reduced Power Wiring Harness: All Technical Service Bulletins Electrical - Intermittent MIL/DTC P2138/Reduced Power TECHNICAL Bulletin No.: 07-06-04-019D Date: June 28, 2010 Subject: Intermittent Malfunction Indicator Lamp (MIL) Illuminated, DTC P2138 with Reduced Engine Power (Repair Instrument Panel (IP) to Body Harness Connector) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years and warranty information. Please discard Corporate Bulletin Number 07-06-04-019C (Section 06 - Engine/Propulsion System) Condition - Some customers may comment on an intermittent malfunction indicator lamp (MIL) being Illuminated with a message or an indicator that displays Reduced Engine Power. - The technician may observe on a scan tool DTC P2138 - Accelerator Pedal Position (APP) Sensor 1-2 Correlation set as Current or in History. Cause This condition may be caused by water intrusion into the instrument panel (IP) to body harness connector, which carries the APP sensor signals to the ECM/PCM. This water intrusion results in a voltage difference between APP Sensor 1 and APP Sensor 2 that exceeds a predetermined value for more than a calibrated period of time, setting P2138. Correction Note Aftermarket equipment can generate DTC P2138 and/or other DTCs. 1. Verify that aftermarket equipment is not electrically connected to any of the APP sensor signal or low reference circuits or to any other ECM/PCM 5V reference or low reference circuits. Refer to Checking Aftermarket Accessories in SI. 2. Perform the Diagnostic System Check - Vehicle. ‹› If any 5V reference DTCs are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle. ‹› If any 5V reference DTCs are not set, proceed to Step 3. 3. Locate the IP to body harness connector, which may be located in and around the left hand kick panel area or inside the IP. Depending on the vehicle and model year, refer to Wiring Systems or Power and Signal Distribution in SI. Note Some examples of potential water leaks are: A-pillar seals, sunroof drain lines (if equipped) and windshield/cowl sealing. 4. Inspect for a water leak in the area. If necessary use a water hose to determine the source of the leak. Refer to General Information > Water Leaks in SI. ‹› If a water leak is observed, repair as necessary. Verify the effectiveness of the repair. 5. Inspect the IP to body harness connector terminals for corrosion and debris. Refer to Testing for Intermittent Conditions and Poor Connections in SI. ‹› If any corrosion and/or debris is observed, repair as necessary. 6. After completing the repair, verify the proper operation of the system. Depending on the vehicle and model year, perform the Diagnostic Repair Verification procedure or refer to Diagnostic Trouble Code (DTC) List - Vehicle in SI. Page 5691 X308 Inline Harness Connector End Views X308 Body Harness to Left Seat Inflatable Restraint Impact Module Jumper Harness and Pretensioner Page 1118 3. If the strut has not been modified previously, perform the following steps before continuing with the wheel alignment: 1. Disconnect the strut from the knuckle. Refer to Strut Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Strut/Strut Assembly Replacement). 2. File the lower hole until the outer flange slot matches the inner flange slot. 3. Connect the strut to the knuckle. Refer to Strut Assembly Replacement (See: Steering and Suspension/Suspension/Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Strut/Strut Assembly Replacement). 4. Adjust the camber to specification by moving the top of the wheel in or out. Refer to Wheel Alignment Specifications (See: Specifications/Wheel Alignment Specifications). Page 9907 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Page 3215 7 - Control Solenoid Valve Assembly w/TCM 16 - Automatic Transmission Output Shaft Speed (OSS) Sensor 19 - Automatic Transmission Input Shaft Speed (ISS) Sensor 609 - Transmission Manual Shift Shaft Switch Page 5559 Rear Compartment Courtesy Lamp Rear Compartment Lid Latch Page 10458 Ambient Light Sensor: Service and Repair Ambient Light Sensor Replacement Page 8237 1 - Connector Positive Assurance (CPA) 2 - Assist Lever 3 - Wiredress Cover 4 - Seal Strain/Relief 5 - Slide Left Hand 6 - Slide Right Hand 7 - Terminal Positive Assurance (TPA) 8 - Terminal Positive Assurance (TPA) 9 - Connector Seal 10 - Connector Housing 11 - Inner Connector Identifying Connectors Knowing the connector manufacturer is helpful when trying to locating the correct connector repair procedure. There are many different connector designs used on GM vehicles and it is sometimes difficult to identify the connector manufacturer. The information in this document should help with the identification of connector manufactures. The following connector manufacturers make most of the connectors found in GM vehicles: * AFL/EPC (Alcoa Fujikura Ltd./Engineered Plastics Components) * Bosch * Delphi * FCI (Framatome Connectors International) * JAE (Japan Aviation Electronics) * JST (Japan Solderless Terminals) * Kostel * Molex * Sumitomo * Tyco/AMP * Yazaki Identifying the manufacturer of a connector is often difficult. When trying to determine the manufacturer of a connector, look for specific identifying marks that are unique to that connector supplier. Most of these identify marks are hard to find or see. Check the connector carefully and refer to the information below for pictures and descriptions of connector identification markings. Page 2084 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in the vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in the vehicle for five years or 240 000 km (150,000 miles), whichever occurs first. The following explains the cooling system and how to check and add coolant when it is low. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. If using this mixture, nothing else needs to be added. This mixture: Gives freezing protection down to -34°F (-37°C). Gives boiling protection up to 265°F (129°C). Protects against rust and corrosion. Will not damage aluminum parts. Helps keep the proper engine temperature. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. NOTICE: If extra inhibitors and/or additives are used in the vehicle's cooling system, the vehicle could be damaged. Use only the proper mixture of the engine coolant listed for the cooling system. Page 9541 Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. Slide the lever lock forward while pressing down on the lever lock release tab. 2. The release tab is located on the top of the wire dress cover. 3. View of connector in released position. 4. Disconnect the connector from the component. 5. Locate the dress cover locking tabs at the corners of the dress cover. Use a small flat-blade tool to release the locking tabs and remove the dress cover. Page 2351 Engine Control Module (ECM) X1 (LY7) Page 7197 Vehicle Lifting: Service and Repair Lifting and Jacking the Vehicle Special Tools J 43625 Lift Pad Adapter Note: The use of a LOW PROFILE LIFT ARMS SYSTEM may be required to avoid unwanted contact with the vehicle's body and structure depending on lifting equipment used. Refer to the manufacture's recommendation for their applications of low profile lift arms system for their lifting equipment. Danger: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist. Danger: To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack. Caution: Perform the following steps before beginning any vehicle lifting or jacking procedure: * Remove or secure all of the vehicle contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure. * The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents. * The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment manufacturer. * Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface. * Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components. Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle contents. Vehicle Lifting - Frame Contact Lift Front Lift Pads Page 6153 Page 10101 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close Page 2138 5. Reposition the heater outlet hose clamp at the engine using the J 38185. 6. Remove the heater outlet hose from the engine. Installation Procedure 1. Install the heater outlet hose to the engine. 2. Reposition the heater outlet hose clamp at the engine using the J 38185. Page 7538 19. Remove and discard the condenser mounting bolts. 20. Remove and discard the condenser mounting nuts. 21. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clip. 22. Remove the condenser. 23. Remove the upper seal. Note: Cap all A/C components immediately to prevent system contamination. 24. Remove and discard the sealing washers. Installation Procedure 1. Uncap A/C components. 2. Install new sealing washers. Refer to Air Conditioning System Seal Replacement (See: Coupler HVAC/A/C Coupler O-ring/Service and Repair/Air Conditioning System Seal Replacement). 3. Install the upper seal. Page 2842 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Page 1874 * The long bolts through the engine mount bracket to the engine block * The short bolt through the engine lift bracket to the engine mount bracket Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Tighten the engine mount bracket bolts in the following sequence: 1. Tighten the engine mount bracket to engine block bolts to 90 Nm (66 lb ft). 2. Tighten the engine lift bracket to engine mount bracket bolts to 33 Nm (24 lb ft). 4. Install the engine mount. Refer to Engine Mount Replacement (See: Engine Mount Replacement). Page 4061 9. Install a NEW snap ring on the output shaft. 10. Install the drive axle assembly. Refer to Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement). 11. Lower the vehicle. 12. Inspect the output axle shaft sleeve for leaks. 13. Inspect the oil level. Refer to Transmission Fluid Level and Condition Check (See: Testing and Inspection/Symptom Related Diagnostic Procedures/4T45-E - Automatic Transmission/Transmission Fluid Level and Condition Check). Front Wheel Drive Shaft Seal and Output Shaft Sleeve Replacement - Right Side Front Wheel Drive Shaft Seal and Output Shaft Sleeve Replacement - Right Side Special Tools * J 6125-1B Slide Hammer * J 8092 Driver Handle * J 23129 Universal Seal Remover * J 38868 Shaft Removal Tool * J 41102-1A Axle Seal Installer * J 41227 Output Shaft Sleeve Remover * J 41228 Output Shaft Sleeve Installer Removal Procedure Note: * The stub axle shaft sleeve and seal must be replaced together. DO NOT replace the sleeve or seal separately. * Do not damage the seal bore or the sleeve assembly. Fluid leaks may result. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the right drive axle assembly. Refer to Wheel Drive Shaft Replacement (See: Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement). Diagrams Seat Belt Tensioner: Diagrams Component Connector End Views Seat Belt Anchor Pretensioner - Driver Seat Belt Pretensioner - Passenger Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor: Service and Repair Camshaft Position Sensor Replacement - Intake Camshaft Position Sensor Replacement - Intake Removal Procedure 1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Cleaner Fresh Air Duct/Hose/Service and Repair/Air Cleaner Outlet Duct Replacement). 2. Disconnect the engine wiring harness electrical connector (7) from the intake camshaft position (CMP) sensor (6). 3. Remove the CMP sensor bolt. 4. Remove the CMP sensor. Installation Procedure Page 7430 Temperature Valve Actuator Replacement Temperature Valve Actuator Replacement Page 8331 Page 3854 Control Solenoid Valve Assembly (MH8) Page 9277 Note: Do not damage any inner panels or reinforcements. 6. Locate and drill out all factory welds. Note the number and location of the welds for installation of the tie bar. 7. Remove the damaged tie bar. Installation Procedure Audio - Radio Does Not Mute Enough When Using OnStar(R) Navigation System: All Technical Service Bulletins Audio - Radio Does Not Mute Enough When Using OnStar(R) TECHNICAL Bulletin No.: 10-08-46-001 Date: January 27, 2010 Subject: Radio Does Not Mute Enough When OnStar(R) Turn-by Turn Navigation Directions Are Announced (Increase Volume Setting or Request Soft Mute Feature Change Through OnStar(R) Customer Service) Models: 2009-2010 GM Passenger Cars and Trucks (Including Saturn) 2009-2010 HUMMER H2, H3 2009 Saab 9-7X All Equipped with OnStar(R) (RPO UE1) Condition Some customers may comment that when the radio is on, it does not mute enough when the OnStar(R) Turn-by-Turn Navigation directions are announced. Cause This condition may be caused by the customer improperly setting the radio volume high enough when the Turn-by-Turn Navigation messages are played. The 2009 and 2010 models with OnStar(R) initiates a "soft mute" feature when the radio is on during Turn-by-Turn Navigation direction announcements. During the announcement, the radio can still be heard at a very low volume. Previous model years initiated a "hard mute" during this function which completely muted the radio audio. Correction Instruct the customer to increase the radio volume while getting the Turn-by-Turn Navigation direction announcements. You can control the message volume using the radio volume control, only when the Turn-by-Turn navigation messages are playing. Some customers that were accustomed to previous model vehicles with the "hard mute" feature may be dissatisfied with the function of the "soft mute" feature. For those customers, contact the OnStar(R) Customer Service Center by pushing the Blue OnStar(R) Button to speak to a trained Advisor and request a change be made to the vehicle from the "soft mute" setting to that of the hard or complete muting of audio playback during Turn by Turn directions. OnStar(R) will then create a case number. Advise the customer that the vehicle update should be completed Over the Air within 5 business days, after which an OnStar(R) Customer Care advisor will follow-up with the customer to verify the fix. If the customer does not hear back from OnStar(R) within a week, advise them to press the Blue OnStar(R) Button and ask for Customer Care to check status. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 2120 Page 1605 Tires: Removal and Replacement Tire Dismounting and Mounting Caution: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Caution: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. Caution: Damage to either the tire bead or the wheel mounting holes can result from the use of improper wheel attachment or tire mounting procedures. It takes up to 70 seconds for all of the air to completely exhaust from a large tire. Failure to follow the proper procedures could cause the tire changer to put enough force on the tire to bend the wheel at the mounting surface. Such damage may result in vibration and/or shimmy, and under severe usage lead to wheel cracking. 1. Remove the valve core from the valve stem. 2. Deflate the tire completely. Note: Rim-clamp European-type tire changers are recommended. 3. Use the tire changer in order to remove the tire from the wheel. Follow steps 4-7 to remove the tire from the wheel. 4. When separating the tire bead from the wheel, position the bead breaking fixture 90, 180 and 270 degrees from the valve stem. Caution: Failure to position valve stem in proper position while dismounting and mounting the tire may result in the TPM sensor to become damaged. 5. Position the wheel and tire so the valve stem is at the 7 o'clock position relative to the head. The tire iron or pry bar can be inserted when prying the outer tire bead up and over the mounting/dismounting head. Service and Repair Air Filter Element: Service and Repair Air Cleaner Element Replacement Removal Procedure 1. Disconnect the engine wiring harness electrical connector (1) from the mass airflow (MAF)/intake air temperature (IAT) sensor. 2. Loosen the air cleaner outlet duct clamp at the air cleaner assembly. 3. Remove the air cleaner outlet duct from the air cleaner assembly. 4. Disengage the air cleaner cover latches (1). 5. Open the air cleaner cover. 6. Remove and discard the air filter assembly. Installation Procedure Page 4865 Brake Fluid Pressure Sensor/Switch: Service and Repair Brake Master Cylinder Pressure Sensor Replacement Engine/Transmission - Aftermarket Calibrations PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine/Transmission Aftermarket Calibrations INFORMATION Bulletin No.: 09-06-04-026C Date: August 13, 2010 Subject: Identifying Non-GM (Aftermarket) Engine and Transmission Calibrations for V8 Gas Engines Using Tech 2(R) or Global Diagnostic System (GDS) Models: 2006-2011 GM Passenger Cars and Light Duty Trucks (Excluding Saab 9-7X) 2006-2009 HUMMER H2 2006-2010 HUMMER H3 Equipped with V8 Gas Powered Engines Only Attention: This bulletin applies to V8 gas powered engines ONLY. For Duramax(TM) diesel powered engines, refer to the latest version of Corporate Bulletin Number 08-06-04-006G. Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-06-04-026A (Section 06 - Engine/Propulsion System). General Motors is identifying an increasing number of engine, transmission and catalytic converter part failures that are the result of non-GM (aftermarket) engine and transmission control calibrations being used. When alteration to the GM-released engine or transmission control calibrations occurs, it subjects powertrain and driveline components (engine , transmission, transfer case, driveshaft and rear axle) to stresses that were not tested by General Motors. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Warranty coverage is based on the equipment and calibrations that were released on the vehicle at time of sale, or subsequently updated by GM. That's because GM testing and validation matches the calibration to a host of criteria that is essential to assure reliability, durability and emissions performance over the life of the warranty coverage and beyond. Stresses resulting from calibrations different from those tested and released by GM can damage or weaken components, leading to poor performance and or shortened life. Additionally, non-GM (aftermarket) issued engine control modifications often do not meet the same emissions performance standards as GM issued calibrations. Depending on state statutes, individuals who install engine control module calibrations that put the vehicle outside the parameters of emissions certification standards may be subject to fines and/or penalties. This bulletin outlines a procedure to identify the presence of non-GM (aftermarket) calibrations. GM recommends performing this check whenever a hard part failure is seen on internal engine or transmission components, or before an engine assembly or transmission assembly is being replaced under warranty. It is also recommended that the engine calibration verification procedure be performed whenever diagnostics indicate that catalytic converter replacement is indicated. The PQC has a process to confirm the ECM/PCM calibration is GM issued. The PQC will require a picture of the engine calibration verification screen, as outlined in this bulletin, before authorizing any V8 gas powered engine replacement. If a non-GM calibration is found and verification has taken place through GM, the remaining powertrain and driveline warranty will be blocked and notated in GMVIS and the dealership will be notified. This block prevents any UNAUTHORIZED warranty claim submission. 1. Connect the Tech 2(R) to the vehicle. 2. Go to: Diagnostics and build the vehicle. 3. Select: Powertrain. 4. Select: Engine. 5. *Select: Engine Control Module or PCM. 6. *Select: Module ID Information or I/M Information System if the Module ID Information selection is not available. 7. *If "I/M information System" was selected, it may be necessary to select "Vehicle Information" in order to display the calibration information. ‹› If the CVN information is displayed as "N/A", it will be necessary to contact the TCSC to obtain the CVN information. Page 9972 * Yellow vinyl electrical tape Pigtail repair packs are available for SIR/SRS connectors with eight or less terminals. Only the connector body is available for connectors with more than eight terminals. The terminated leads in the J-38125 SIR/SRS Terminal Repair Kit can be used to replace damaged terminals when replacing the connector body. SIR/SRS Component Wire Pigtail Repair Note: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device, not by a connector. If a wiring pigtail is damaged, you must replace the entire component, with pigtail. The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Note: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Wiring Repairs/Wiring Repairs) If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 Use the following wiring repair procedures in order to ensure the integrity of the DuraSeal splice sleeves. Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: * Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. * Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial. * Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. Page 7919 6. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals on to the bare wire using the J38125-7 crimp tool, jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 7. Position the wire seal to the terminal and crimp the seal and insulation using the J-38125-6 crimp tool, jaw 1 (1). The completed terminal and seal should appear as shown above (body harness connector shown). Note Avoid getting solder on the terminal end or overheating the terminal. Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. 8. Solder all four terminals at the wire crimp. 9. Slide the two body harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Page 3615 Shift Interlock Solenoid: Diagrams Component Connector End Views Automatic Transmission Shift Lock Control Solenoid Page 8222 The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and +71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Duplicating Failure Conditions * If none of the previous tests are successful, attempt to duplicate and/or capture the failure conditions. * Freeze Frame/Failure Records data, where applicable, contains the conditions that were present when the DTC set. 1. Review and record Freeze Frame/Failure Records data. 2. Clear the DTCs using the scan tool. 3. Turn the key to OFF and wait 15 seconds. 4. Operate the vehicle under the same conditions that were noted in Freeze Frame/Failure Records data, as closely as possible. The vehicle must also be operating within the Conditions for Running the DTC. Refer to Conditions for Running the DTC in the supporting text if a DTC is being diagnosed. 5. Monitor DTC Status for the DTC being tested. The scan tool will indicate Ran, when the enabling conditions have been satisfied long enough for the DTC to run. The scan tool will also indicate whether the DTC passed or failed. * An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the concern occurs, may help you locate the concern. Measuring Frequency Measuring Frequency Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedure determines the frequency of a signal. Note: Connecting the Digital Multimeter (DMM) to the circuit before pressing the Hz button will allow the DMM to auto range to an appropriate range. 1. Apply power to the circuit. 2. Set the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Set to Hz on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage Measuring Voltage Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). Page 5465 Evaporative Emission (EVAP) Canister Vent Solenoid Valve Fo - Ge Component Connector End Views Fog Lamp - Left Front (T96) Page 3302 4. Using the adjustable jack, raise the right side of the fuel tank. 5. Install the right side rear fuel tank strap (1) bolt. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 6. Tighten the left side fuel tank strap (2) bolts to 20 Nm (15 lb ft). 7. Tighten the right side front fuel tank strap bolt to 20 Nm (15 lb ft). 8. Remove the support from the fuel tank. 9. Install the fuel fill pipe hose to the fuel tank. 10. Connect the fuel tank fill EVAP emission pipe quick connect fitting (2) to the fuel tank fill EVAP emission pipe (1). Refer to Plastic Collar Quick Connect Fitting Service (See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair/Plastic Collar Quick Connect Fitting Service). 11. Tighten the fuel fill pipe hose clamp (3) at the fuel tank to 4 Nm (35 lb in). Page 6484 Battery (+) X2 (LAT) Battery (-) Battery Current Sensor (HP7) Battery Current Sensor (LAT or LE5 or LY7 or LE9) Page 9938 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 5407 Courtesy Lamp - Left Front Door Courtesy Lamp - Right Front Door Page 3175 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 9038 Center Pillar Upper Garnish Molding Replacement Center Pillar Upper Garnish Molding Replacement Page 5706 Campaign - Airbag Readiness Light/Service Airbag Message Technical Service Bulletin # 10085D Date: 110203 Campaign - Airbag Readiness Light/Service Airbag Message CUSTOMER SATISFACTION Bulletin No.: 10085D Date: February 03, 2011 Subject: 10085D - Airbag Readiness Light/Service Airbag Message - Replace Connectors Models: 2008 Buick Enclave 2010 Chevrolet Malibu 2008 GMC Acadia 2010 Pontiac G6 2008 Saturn OUTLOOK Supercede: The Service Procedure in this bulletin has been revised. All vehicles will not require the replacement of the front seat-mounted side impact airbag connectors.Please discard all copies of bulletin 10085C, issued November 2010. Condition Certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles may experience wear which could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact air bag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG System warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG System DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Correction Dealers are to replace the front seat-mounted side impact airbag connectors. Vehicles Involved Involved are certain 2008 model year Buick Enclave, GMC Acadia, and Saturn OUTLOOK vehicles, and 2010 model year Chevrolet Malibu and Pontiac G6 vehicles built within these VIN breakpoints: Important Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Required Field Actions section in the Global Warranty system. Not all vehicles within the above breakpoints may be involved. For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Part Information Parts required to complete this program are to be obtained from General Motors Customer Care and Aftersales (GMCC&A;). Please refer to your Page 1507 Tire Pressure Sensor: Testing and Inspection Tire Pressure Indicator Sensor Learn Special Tools J-46079 Tire Pressure Monitor Diagnostic Tool Learn Mode Description The tire pressure monitor (TPM) system uses the instrument panel cluster (IPC), body control module (BCM), remote control door lock receiver (RCDLR), keyless entry transmitter, 4 radio frequency transmitting pressure sensors, and the serial data circuit to perform the TPM learn mode functions. The sensor learn procedure must be performed after every tire rotation, RCDLR replacement, or sensor replacement. Once the learn mode has been enabled, each of the sensors unique identification codes can be learned into the RCDLR memory. When a sensor ID has been learned, the RCDLR sends a serial data message to the BCM to sound a horn chirp. This verifies the sensor has transmitted its ID and the RCDLR has received and learned it. The RCDLR must learn the sensor IDs in the proper sequence to determine correct sensor location. The first learned ID is assigned to the left front location, the second to right front, the third to right rear and the fourth to left rear. The turn signals will individually illuminate indicating which location is to be learned in the proper sequence. Sensor Functions Using J-46079 Each sensor has an internal low frequency coil. When the J-46079 is used in activate mode, it produces a low frequency transmission that activates the sensor. The sensor responds to a low frequency activation by transmitting in learn mode. When the RCDLR receives a learn mode transmission while in TPM learn mode, it will assign that sensors ID to the location on the vehicle relative to the order in which it was learned. Sensor Functions Using Pressure Increase/Decrease Method Each sensor takes a pressure measurement sample once every 30 seconds while in stationary mode. If the tire pressure increases, or decreases by more than 8.3 kPa (1.2 psi) from the last pressure measurement, another measurement will occur immediately to verify the change in pressure. If a pressure change has indeed occurred, the sensor transmits in Learn mode. When the RCDLR receives a Learn mode transmission while in TPM learn mode, it will assign that sensor's ID to the location on the vehicle relative to the order in which it was learned. Learn Mode Cancellation The learn mode will cancel if the ignition is cycled to OFF or if more than 2 minutes has elapsed for any sensor that has not been learned. If the learn mode is cancelled before the first sensor is learned, the original sensor IDs will be maintained. If the learn mode is canceled after the first sensor is learned, the following will occur: * All stored sensor IDs will be invalidated in the RCDLR memory. * If equipped, the DIC will display dashes instead of tire pressures. * DTC C0775 will be set. These conditions will now require the learn procedure to be repeated for the system to function properly. TPM Learn Procedure Note: If using the scan tool to enable the learn mode, the J-46079 must be used to activate the sensors. When this preferred method is used, any stray sensor signals will not affect the learn procedure. In the event a particular sensor's information is displayed on the special tool upon activation but the horn does not chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. If using the keyless entry transmitter or DIC buttons to enable the learn mode, the J-46079 or Pressure Increase/Decrease Method may be used. Before proceeding with this method, ensure that no other learn procedure is being performed simultaneously or that tire pressures are not being adjusted on another TPM equipped vehicle within close proximity. Stray signals from other TPM equipped vehicles just driving by can be inadvertently learned. If any random horn chirps are heard from the vehicle while performing the learn procedure, most likely a stray sensor has been learned and the procedure will need to be cancelled and repeated. Under these circumstances, performing the TPM Learn Procedure away from other vehicles would be highly recommended. In the event a particular sensor activation does not cause the horn to chirp, it may be necessary to rotate the wheel valve stem to a different position due to the sensor signal is being blocked by another component. Preferred Scan Tool Learn Enable Method 1. Using a scan tool, initiate the TPM Learn Mode. A double horn chirp will sound indicating the Learn Mode has been enabled. The left front turn signal will also be illuminated. 2. Starting with the left front tire, active the sensor by holding the antenna of the J-46079 aimed upward against the tire sidewall close to the wheel rim at the valve stem location. Press and release the Activate button and wait for a horn chirp. Once the horn chirp has sounded, the sensor information is learned and the turn signal in the next location to be learned will illuminate. Page 9325 Note: Do NOT kink the cables. 2. Feed the sunroof drive cables through the drive tubes. 3. Install the sunroof cable drive tube retainers into the ends of the sunroof window track assembly. Ensure that the retainers are fully seated in the track assembly. Locations Steering Control Module: Locations Instrument Panel/Center Console Component Views Instrument Panel Components - Steering Column 1 - Inflatable Restraint Steering Wheel Module Coil 2 - Power Steering Control Module (PSCM) Page 7213 9. Learn the tire pressure sensors. Refer to Tire Pressure Indicator Sensor Learn (See: Testing and Inspection). Page 9515 (dock and lock) connector. * Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. * After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure Scan Tool Snapshot Procedure Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: * Snapshot - taken from the Snapshot menu choice * Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing for Continuity Testing for Continuity Special Tools EL 39200 - Digital Multimeter (DMM) For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Caution: Refer to Test Probe Caution (See: Service Precautions/Vehicle Damage Warnings/Test Probe Caution). The following procedures verify good continuity in a circuit. With a Digital Multimeter (DMM) 1. Set the DMM to the Ohms position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Select the MIN MAX function on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance, the circuit has good continuity. With a Test Lamp Note: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect one lead of the test lamp to one end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Page 5225 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Page 1656 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Page 10011 Page 758 Turn Signal Switch: Service and Repair Turn Signal Multifunction Switch Replacement Turn Signal Multifunction Switch Replacement Page 9424 Page 6687 Your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle not only meets, but exceeds government standards for side impact protection. GM recently introduced into production, changes that add to that protection. At no charge, your dealer will make similar changes to your vehicle, which was built before the production change. What We Will Do: To enhance the side impact protection, your GM dealer will update the wiring harness for both front seat side impact airbags. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation: If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 10085 Page 6959 19. Install the connector to the sensor. 20. From the technicians point of view, the FRONT of the sensor will have: * A pin hole (3) for the centering pin-Note location of the pin hole. * A flush rotor flange cuff (5) * An alignment mark (4) for installation * A foam ring (6) 21. From the technicians point of view, the BACK of the sensor will have: * Double D flats (1) * An alignment tab (2) for installing the sensor to the adapter and bearing assembly Note: If you are reusing the existing sensor, align the marks on the flush rotor flange cuff before installation. The alignment mark must stay aligned until the sensor is seated into the adapter and bearing assembly. If you are installing a new sensor, the new sensor will come with a pin. Do not remove the pin until the sensor is seated. If the pin is not installed in the sensor, order a new sensor. 22. Looking at the FRONT of the sensor, align the sensor with the steering shaft and install the sensor to the adapter and bearing assembly. 23. Install the connector to the sensor. Page 2543 Capacity Specifications Refrigerant Oil: Capacity Specifications Abrupt Refrigerant Loss ....................................................................................................................... ...................................................... 60 ml (2.0 oz) (1) Compressor Replacement The service compressor for the LY7 engine is precharged with 150 ml (5 oz) of PAG oil. The service compressor for the LAT, LE5, LZ4 and LZE engines are precharged with 74 ml (2.5 oz) of PAG oil. Condenser Replacement ..................................................................................................................... ........................................................ 30 ml (1.0 oz) (2) Evaporator Replacement ............................... ............................................................................................................................................. 45 ml (1.5 oz) (2) Total System PAG Oil Capacity ............................................................................................... ..................................................................... 150 ml (5.0 oz) 1)Abrupt refrigerant loss due to large leak, hose rupture, collision, or pressure relief valve opening. Conditions that allow the refrigerant to seep or bleed off over time do not cause this oil loss. Upon replacement of a component that caused a large refrigerant loss, also add the required amount of oil for the particular component. (2)If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. Page 5285 Warranty Information (Saab U.S. Models) Disclaimer Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Page 7554 * Use TXL type wire Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Page 2020 Variable Valve Timing Solenoid: Diagrams Component Connector End Views Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust (LY7) Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake (LY7) Page 5720 Power Distribution Module: Diagrams Component Connector End Views Accessory AC/DC Power Control Module X1 (KV1) Accessory AC/DC Power Control Module X2 (KV1) Page 1467 Service and Repair Door Lock Cylinder: Service and Repair Door Lock Cylinder Replacement Specifications Axle Nut: Specifications Front axle nut ....................................................................................................................................... .................................................... 215 Nm (159 lb ft) Page 2369 Engine Control Module: Service and Repair Engine Control Module Replacement Removal Procedure Caution: * Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. * Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. * In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. * Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. * The replacement control module must be programmed. Note: It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change. 1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life. 2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 3. Disconnect the body wiring harness electrical connector (1) from the engine control module (ECM). Page 9176 8. Use a small flat-blade tool to pry the other side of the piece to the pre-stage position. If the nose piece is higher than the first step in the nose piece, gently push down on the nose piece until it meets with resistance from the connector body, you should feel the nose piece click into position. 9. Insert the J 38125-213 into the small terminal release hole on the nose piece and gently pull on the back of the wire. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. Page 2231 5. Remove the HO2S using the J 39194-B. 6. Remove the exhaust manifold heat shield bolts and shield. Engine Controls - MIL ON/DTC P0172 Set Engine Control Module: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0172 Set TECHNICAL Bulletin No.: 10-06-04-004A Date: January 13, 2011 Subject: Intermittent Illumination of Malfunction Indicator Lamp (MIL)/Check Engine Light, DTC P0172 Set (Verify Alcohol Content Information in PCM) Models: 2010 Chevrolet Malibu Equipped with 2.4L 4 Cylinder Engine (VINs B, 0 - RPOs LE5, LE9) Please refer to GWM/IVH Supercede: This bulletin is being revised to update the engine type codes. Please discard Corporate Bulletin Number 10-06-04-004 (Section 06 - Engine/Propulsion System). Condition Some customers may comment on an intermittent illumination of the malfunction indicator lamp (MIL)/check engine light. Technicians may find a DTC P0172 set. Correction Use the procedure below to determine if the PCM has the incorrect alcohol content information. 1. Verify the actual measured percentage of alcohol content using the J-44175-A tester. Refer to Alcohol in Fuel Diagnosis in SI. If the actual alcohol is less than 15%, determine the "Fuel Alcohol Content" using the Tech 2(R). 2. Install the Tech 2(R) and build the vehicle as a 2010 and select Powertrain. 3. Build the vehicle with an LE9 engine (even if it has the LE5 engine). - Select Special Functions. - Select Fuel System (F2). Page 7751 Service and Repair Seat Belt Guide Track: Service and Repair Driver or Passenger Seat Shoulder Belt Guide Adjuster Replacement Page 165 Control Module HVAC: Diagrams Component Connector End Views Blower Motor Control Module (C68) Page 4830 Front Brake Caliper Hardware Replacement Front Brake Caliper Hardware Replacement Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning). 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding. 3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 4. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair). 5. Using a C-clamp installed to the center of the outer brake pad and the back of the caliper, slowly compress the caliper piston into its bore just enough to remove the caliper from the mounting bracket. Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 6. To loosen the brake caliper pin bolts, hold the brake caliper guide pin with a wrench. 7. Remove the lower brake caliper pin bolt. 8. Pivot the brake caliper upward and support with mechanics wire as shown. 9. Remove the brake pads (2) from the disc brake caliper bracket. Page 2153 1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the lower radiator air deflector retainers. 3. Remove the lower radiator air deflector. Installation Procedure Important: Radiator air deflector must be properly installed or reduced A/C and engine cooling system performance could occur. 1. Install the lower radiator air deflector. 2. Install the lower radiator air deflector retainers. 3. Lower the vehicle. Radiator Air Upper Baffle and Deflector Replacement Radiator Air Upper Baffle and Deflector Replacement Page 1649 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Page 3765 Note All pictures must be sent as a.jpg file. 27. E-mail a copy of the screenshot to [email protected]. In the subject line of the e-mail include the phrase "V8 Cal" as well as the complete VIN and Dealer BAC. In the body of the e-mail, include the VIN, mileage, R.O. number and BAC. Include a brief description of the customer concern and cause of the concern. Note The dealer will receive an e-mail reply after the calibrations have been validated. The e-mail reply will advise the dealer if the calibrations are OEM. 28. Allow two hours for the PQC to verify the calibrations and set up the case details. ‹› If the PQC determines that the calibrations ARE aftermarket calibrations, DO NOT contact GM Technical Assistance to discuss warranty concerns on the aftermarket calibrations. ALL questions and concerns about warranty should be directed to the dealers Fixed Operations Manager (FOM), (Warranty Manager (WM) in Canada). 29. You may call the PQC two hours after submitting the e-mail for authorization to replace the assembly. This will provide them time to receive, review and set up a case on the request. Please be prepared to provide all the usual documentation that is normally required when requesting an assembly authorization from the PQC. Warranty Information - The Dealership Service Management must be involved in any situation that would justify the use of labor operation Z1111. - Notify the Fixed Operations Manager (FOM) (Warranty Manager (WM) in Canada) of the situation. - All claims will have to be routed to the FOM (WM in Canada) for approval. - Please refer to Corporate Bulletin Number 09-00-89-016, Labor Operation Z1111 - Suspected Tampering or Vehicle Modifications for important information. For vehicles repaired under warranty, use the table. Disclaimer Page 1604 Always use a 4-wheel rotation. After rotation, check the wheel nuts for specified torque. Then set the tire pressure. Page 779 Camshaft Position (CMP) Sensor - Bank 2 Exhaust (LY7) Locations Compressor Clutch Relay: Locations Electrical Center Identification Views Fuse Block - Underhood Label (LAT) Fuse Block - Underhood Label (except LAT) Page 8272 5. Once the nose piece retainers are relaxed, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should raise slightly. 6. On the opposite side of the nose piece, use the J 38125-552 to pull up the nose piece by hooking the tool under the nose piece and pulling up. The nose piece should release completely. If the nose piece does not come off, repeat the procedure on the opposite side. Page 7185 Wheel Bearing: Service and Repair Rear Suspension Rear Wheel Bearing and Hub Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Wheels and Tires/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Wheels and Tires/Service and Repair). 3. Remove the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 4. Disconnect the electrical connector from the wheel speed sensor. 5. Remove the 4 wheel bearing/hub assembly nuts. 6. Remove the wheel bearing/hub assembly from the knuckle. Installation Procedure TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Page 7864 1 - Inflatable Restraint Roof Rail Module - Right Front 2 - Inflatable Restraint Roof Rail Module Left Front 3 - Yaw and Lateral Accelerometer Sensor 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Page 8325 Communications Control Module: Service and Repair Communication Interface Module Bracket Replacement Communication Interface Module Bracket Replacement Page 422 Page 6482 Automatic Transmission Shift Lock Control Solenoid Backup Lamp - Left Page 2930 Knock Sensor: Diagrams Component Connector End Views Knock Sensor (KS) (LAT or LE5 or LE9) Knock Sensor (KS) 1 (LZ4 or LZE or LY7) Page 625 1 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Intake 2 - Camshaft Position (CMP) Sensor - Bank 1 Intake 3 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 4 - Intake Manifold Tuning (IMT) Solenoid Valve 5 - Camshaft Position (CMP) Sensor - Bank 2 Intake 6 Manifold Absolute Pressure (MAP) Sensor 7 - Throttle Body 8 - Ignition Coil 6 9 - Ignition Coil 4 10 - Ignition Coil 2 11 - Heated Oxygen Sensor (HO2S) - Bank 2 Sensor 1 12 - Engine Coolant Temperature (ECT) Sensor 13 - Generator 14 - A/C Compressor Clutch 15 - Camshaft Position (CMP) Sensor - Bank 2 Exhaust 16 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Exhaust 17 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 2 Intake 18 - Camshaft Position (CMP) Actuator Solenoid Valve - Bank 1 Exhaust 19 - Camshaft Position (CMP) Sensor Bank 1 Exhaust Page 1112 Alignment: Testing and Inspection Trim Height Inspection Trim Height Measurement Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause the vehicle to bottom out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: * Set the tire pressure to the specifications shown on the certification label. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). * Check the fuel level. Add additional weight if necessary to simulate a full tank. * Make sure the passenger and rear compartments are empty, except for the spare tire. * Make sure the vehicle is on a flat and level surface, such as an alignment rack. * Check that all the vehicle doors are securely closed. * Check that the vehicle hood and rear deck lids are securely closed. * Check for installed after market accessories or modifications that could affect trim height measurement. Measuring the P and R Dimension Important: All dimensions are measured vertical to the ground. Trim height should be within ±10 mm (±0.39 in) to be considered correct. Use the following procedure to check the P and R dimensions: 1. Lift the front bumper of the vehicle up about 38 mm (1.5 in). 2. Gently remove your hands and let the vehicle settle. 3. Repeat this operation 2 more times for a total of 3. 4. P height is measured vertically from the ground to the bottom lip of the wheel opening through the centerline of the front wheel. 5. Push the front bumper of the vehicle down about 38 mm (1.5 in). 6. Gently remove your hands and let the vehicle settle down. 7. Repeat this operation 2 more times for a total of 3. 8. Measure the P height as in step 4. 9. The true P height measurement is the average of the measurements taken in step 4 and 8. 10. Repeat the above steps on the rear of the vehicle for the R heights Measuring the Z Dimension Page 8015 1 - Inflatable Restraint Roof Rail Module - Right Front 2 - Inflatable Restraint Roof Rail Module Left Front 3 - Yaw and Lateral Accelerometer Sensor 4 - Inflatable Restraint Sensing and Diagnostic Module (SDM) Service and Repair Compact Disc Player (CD): Service and Repair Compact Disc Care and Cleaning Care of CDs Handle CDs carefully. Store them in their original cases or other protective cases and away from direct sunlight and dust. The CD player scans the bottom surface of the disc. If the surface of a CD is damaged, such as cracked, broken, scratched, or wrinkled labeling, the CD will not play properly or not at all. If the surface of a CD is soiled, take a soft, lint free cloth or dampen a clean, soft cloth in a mild, neutral detergent solution mixed with water, and clean it. Make sure the wiping process starts from the center to the edge. Do not touch the bottom side of a CD while handling it. This could damage the surface. Pick up CDs by grasping the outer edges or the edge of the hole and the outer edge. Care of the CD Player The use of CD lens cleaners for CD players is not advised, due to the risk of contaminating the internal lens of the CD optics with lubricants. Stuck CDs Interrupting the battery power by pulling the fuse will sometimes release a stuck CD. If a CD is stuck, and removed, inspect it for warps, cracks, etc. If the CD is damaged, do not replace the radio. Labeling CDs Paper labels can eventually warp and wrinkle, and this will cause the disc to jam inside the CD player. Try labeling the top of the discs with a soft magic marker instead. Page 357 Page 9273 Paint: Application and ID Paint Identification Paint Identification Warning Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Note: Always refer to GM Approved Refinish Materials. This information identifies the paint systems you may use. The latest revision of GM Approved Refinish Materials is located on the Goodwrench website at www.gmgoodwrench.com. Use the service parts identification label to identify the type of paint technology, paint codes, trim level, and any special order paint colors on the vehicle. Refer to Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label (See: Application and ID/Vehicle Certification, Tire Placard, Anti-Theft and Service Parts ID Label). Page 5279 Warranty Information (Saab U.S. Models) Disclaimer Page 5880 For vehicles repaired under warranty, use the table. Disclaimer Electrical - Various Electrical Concerns/False Messages Door Switch: Customer Interest Electrical - Various Electrical Concerns/False Messages TECHNICAL Bulletin No.: 09-08-64-022A Date: March 24, 2010 Subject: Various Intermittent Electrical Concerns - Door Ajar Message, Interior Lights On, Theft Deterrent Alarm, Retained Accessory Power (RAP) Stays On, Discharged Battery (Diagnose/Repair Door Lock Assembly/Circuit) Models: 2006-2010 Chevrolet Malibu 2006-2009 Pontiac G6 2006-2009 Saturn AURA Supercede: This bulletin is being revised to add the 2010 model year. Please discard Corporate Bulletin Number 09-08-64-022 (Section 08 - Body and Accessories). Condition Some customers may comment on one or more of the following concerns: - The door ajar message stays on or comes on intermittently. - The interior lights stay on or turn on intermittently. - The content theft deterrent alarm goes off intermittently. - RAP does not cancel when the door is opened allowing the radio, power windows, sunroof and the compass to remain powered up. - The battery is discharged. Cause These conditions may be caused by water intrusion into the door ajar switch (part of the door lock assembly) which causes an incorrect switch status input to the BCM. This condition can be intermittent and wet weather may aggravate this condition. Correction Use the following steps to aid in diagnosis of the concern. Important DO NOT replace the body control module (BCM) for this concern. 1. Use the Tech 2(R) and monitor the door ajar switch inputs to the BCM. The Tech 2(R) lists the left front door separately, then all passenger doors together. 2. Check if a door ajar message is active with the doors closed. If this condition is not present, washing the vehicle may induce the concern. Note that the vehicle may have to sit for up to two hours. 3. If the concern is the RAP does not cancel when the left front door is opened, suspect the left door lock assembly. If the door ajar message is active on the passenger door, it could be any of the other doors. 4. Try opening and closing each passenger door one at a time while monitoring the door ajar status to see if one of the doors will cause the message to change to door closed. If it does, suspect that door lock. 5. If the message does not change, you can isolate which door is indicating ajar by disconnecting the individual door electrical connector at the pass-through on the pillar side. Always start with the right front door first. If the message changes to door closed when the door is disconnected, suspect that door lock. Once you have identified the suspect door, refer to SI for complete circuit testing. Refer to Diagnostic Starting Point - Vehicle Access in SI. Warranty Information Important Use the appropriate labor operation for the repair performed. Electrical - Various Electrical Systems Malfunctions Wiring Harness: All Technical Service Bulletins Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Page 2568 Note: Rotate the pigtail 90 degrees from vertical before securing the fastener. 1. Install the knock sensor. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the knock sensor bolt and tighten to 25 Nm (18 lb ft). 3. Install the knock sensor electrical connector pigtail (6) clip to the oil level indicator tube bracket. 4. Connect the engine wiring harness electrical connector (1) to the knock sensor pigtail electrical connector (6). 5. Lower the vehicle. 6. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Page 1077 Washer Fluid Level Switch: Service and Repair Windshield Washer Solvent Level Indicator Replacement Removal Procedure 1. Remove the front wheelhouse panel splash shield. Refer to Front Wheelhouse Panel Splash Shield Replacement (See: Body and Frame/Fender/Front Fender/Front Fender Liner/Service and Repair/Front Wheelhouse Panel Splash Shield Replacement). 2. Disconnect the washer solvent container level sensor electrical connector. 3. Using a small flat-bladed tool, remove the washer solvent level indicator (4) from the washer solvent container (1). 4. Contain all lost windshield washer solvent into a suitable clean container. 5. Using a small flat-bladed tool, remove the level indicator seal (3) from the washer solvent container (1). Installation Procedure Restraint System - Normal Safety Belt Locking Conditions Seat Belt Retractor: Technical Service Bulletins Restraint System - Normal Safety Belt Locking Conditions INFORMATION Bulletin No.: 05-09-40-002E Date: October 21, 2010 Subject: Safety Belt Locking Conditions (Normal Operating Characteristic) Models: 2005-2011 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2005-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 05-09-40-002D (Section 09 - Restraints). The purpose of this bulletin is to explain when the safety belts are supposed to lock. There are several different locking situations for both front and rear safety belts. Overspool Lock There is an unintentional locking condition that ALL safety belts from ALL manufacturers may experience called "overspool lock". If the webbing snaps back to the stowed position rapidly enough, the retractor will lock with the belt fully stowed. This is more likely to occur when customers "help" the belt to retract. Without the weight of the latch plate and friction to slow the retractive speed of the webbing, the higher than normal webbing retraction speed that occurs engages the locking mechanism when a sudden stop occurs at the end of web travel. Since the webbing is now fully loaded on the spool, the retractor cannot rewind itself further to release the locking mechanism. When this happens, the occupant cannot extract the belt to wear it. DO NOT replace the retractor for this condition until first attempting to disengage the locking mechanism by following the recommendation listed below. Recommendation Pull hard on the locked webbing and then release. The hard pull extracts a small amount of webbing from the retractor which, in turn, permits a small amount of retraction to occur when released. This is all that is needed to disengage the locking mechanism. The safety belt will now function properly. Vehicle Sensing This type of locking occurs in response to the vehicle under the following conditions: - The vehicle changes speed or direction abruptly (the vehicle goes into rapid acceleration OR rapid deceleration or there is aggressive cornering). - It can also occur in a static condition when a vehicle is parked on a large slant (fore-aft or side-to-side), such as streets in San Francisco, California. - It may also occur over rough road conditions where the retractor mechanism is bounced into a locked condition. In all of these conditions, as long as tension is maintained on the webbing, the belt will stay locked. When the tension is released, the belt retracts slightly, the lock bar disengages and the safety belt should return to normal function. Please inform customers that may comment that "the belt locks intermittently" that this is the design intent and the belt is functioning properly. Web Sensing This type of locking occurs in response to the extraction of webbing. When the webbing reels out at an accelerated rate, it goes into lock mode and stays there until tension is again released. To observe this condition, extract the webbing quickly. Customers may refer to this condition as "intermittent lock-up" and encounter it when trying to put the belt on too quickly. Automatic Locking (ALR) When the webbing is pulled all the way out, it automatically converts the retractor into a cinch-down mode (i.e. ALR). This is typically used to tightly secure a child seat to the vehicle. Some customers may experience inadvertent activation of ALR mode if they happen to pull the belt all the way out to the end of travel while they are putting the belt on. The ALR mode of operation is automatically cancelled when the belt is unfastened and stowed (the belt returns to normal sensitive function). Corvette only - This locking mechanism is also provided at the driver's position of the Corvette only, as a unique feature. Corvette customers may find this feature appealing when they plan to operate the vehicle in a "spirited" manner (such as driving in mountainous terrain). With the ALR active, the operator is snugly cinched into the seat and kept firmly in place during high G-force driving maneuvers. Page 3921 Fluid - A/T: Service and Repair Transmission Fluid Replacement Page 9165 6. Use a small flat-blade tool to slide the terminal position assurance (TPA) up one notch on both ends of the connector. The TPA is located underneath the wire dress cover. For the larger terminals insert the J 38125-556 tool to release the terminals by inserting the tool into the terminal release cavity. For the smaller terminals insert the J 38125-560 tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. Locations Camshaft Position Sensor: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch Page 353 4. Connect the body wiring harness electrical connector (1) to the ECM. 5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 6. Program the ECM. Refer to Control Module References (See: Testing and Inspection/Programming and Relearning). Page 9163 9. Insert the J 38125-12A tool to release the terminals by inserting the tool into the terminal release cavity. See the release tool cross reference in the Reference Guide of the J-38125 to ensure that the correct release tool is used. 10. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. FCI Connectors FCI Connectors Page 116 Heated Seat Control Module - Driver X3 (KA1) Page 6490 Body Control Module (BCM) X2 Page 9901 Page 1174 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Page 7111 1. Slide the steering wheel position sensor into place and remove the locating pin. 2. Connect any electrical connectors as needed. 3. Connect the intermediate steering shaft to the steering column. Refer to Intermediate Steering Shaft Replacement (See: Steering/Steering Column/Service and Repair/Intermediate Steering Shaft Replacement). 4. Remove anti-rotation pin J 42640. Page 1698 6. Remove the wheel bearing/hub mounting bolts (1). 7. Remove the wheel bearing/hub and backing plate from the steering knuckle. Page 3065 Locations Starter Motor: Locations Powertrain Component Views Front and Left Side of the Engine Components (LAT or LE5 or LE9) 1 - Manifold Absolute Pressure (MAP) Sensor 2 - Camshaft Position (CMP) Actuator Solenoid Valve - Intake 3 - Camshaft Position (CMP) Actuator Solenoid Valve - Exhaust 4 - Ignition Coil 1 5 Ignition Coil 2 6 - Ignition Coil 3 7 - Ignition Coil 4 8 - Evaporative Emission (EVAP) Canister Purge Solenoid Valve 9 - Camshaft Position (CMP) Sensor - Exhaust 10 - Camshaft Position (CMP) Sensor - Intake 11 - Engine Oil Pressure (EOP) Switch 12 - Starter Motor 13 - Starter Solenoid (part of Starter Motor) 14 - Throttle Body 15 - A/C Compressor Clutch 16 - Generator (LE5 or LE9) or Starter Generator (KY1) Locations Battery Current Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (without LAT or HP7) 1 - Windshield Wiper Motor 2 - Master Cylinder 3 - Electronic Brake Control Module (EBCM) 4 Fuse Block - Underhood 5 - Engine Control Module (ECM) 6 - Transmission Control Module (TCM) (MN5) 7 - Battery 8 - Battery Current Sensor (LE5 or LE9 or LY7) 9 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 10 - Brake Fluid Level Switch Page 6431 Tail/Stop and Turn Signal Lamp - Right (LTZ) Page 9599 Page 6181 Fuse Block - Rear X4 Page 9706 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. Page 9865 Page 6344 Ignition Coil 3 (LY7) Page 9092 Page 4040 8. Remove the control valve body bolt (3) M6 x 42. 9. Remove the 3 control valve body bolts (2) M6 x 95. 10. Remove the control valve body bolt (7) M6 x 55. 11. Remove the control solenoid valve body and transmission control module (TCM) assembly (5). Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 12. Remove the control solenoid valve assembly filter plate (6). * Discard the filler plate. It is not reusable. * Inspect the pressure switch manifold seals for damage or contamination. Replace the control solenoid valve assembly as necessary. * Inspect the upper channel plate bolt holes for damage, peening or burnelling. Any damage around the bolt holes near the pressure control switch (PCS) feed holes could cause leakage around the PCS seals. Replace the upper channel plate as necessary. Installation Procedure Caution: Use care when removing or installing the filter plate assembly. A broken or missing retaining tab may not adequately secure the filter plate to the control solenoid valve assembly, resulting in possible damage or contamination. 1. Install a NEW control solenoid valve assembly filter plate (1). Page 6338 I/P Dimmer Switch Page 8352 1. Check the version of the iPod/MP3 to confirm that it is supported. 2. Unplug and Re-insert the iPod to verify the customer complaint. 3. Verify the battery charge of the iPod. A low battery condition on the iPod may not allow it to connect to the radio. The iPod may need to be charged before it can be controlled by the radio. 4. If the customer receives a "Device Not Supported" message on their radio or is having general iPod/MP3 connection issues (and they have a supported device), they may need to reset their iPod. To reset the iPod: - For the iPod Nanos and Classic , Toggle the Hold switch on and off. (Slide it to Hold, then turn it off again. Press and hold the Menu and Center (Select) buttons simultaneously until the Apple logo appears, about 6 to 8 seconds. You may need to repeat this step. - For the iPod Touch and iPhone: Press and hold the Sleep/Wake button for a few seconds until the red slider appears, then slide the slider. 5. Have the customer check their cable for quality. - Aftermarket cables can wear from use. The customer may need to purchase a new USB cable. - Verify that cable extensions are not present. The extra capacitance may cause too large a signal drop for the iPod to communicate with the radio. 6. If the customer receives a "Device Not Supported" message on their radio with an iPod connected (and they have a supported device), the customer may need to download the latest firmware from the Apple website (Please visit www.apple.com for more information). Validated Apple Device - Both Charge/Support Digital Audio (For All RPOs) For further information on identifying iPod models, please visit http://support.apple.com/kb/ht1353 Other Validated Device- Both Charge/Support Digital Audio for Buick LaCrosse, Chevrolet Camaro, Equinox Only (RPO KTA or KTB) Important: Must be set to MTP (Mass Transfer Protocol) in the MP3 Player device setting. Page 9327 6. Install the sunroof module. Refer to Sunroof Frame Replacement (See: Sunroof / Moonroof Frame/Service and Repair). 7. Initialize the sunroof motor. Refer to Sunroof Motor/Actuator Initialization/Teach Process (See: Sunroof / Moonroof Motor/Testing and Inspection). 8. Inspect the sunroof for proper operation. Page 8276 For equivalent regional tools, refer to Special Tools (See: Power and Ground Distribution/Tools and Equipment). Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a Digital Multimeter (DMM) at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gauge size. Repairing a Fusible Link Note: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Flat Wire Repairs Flat Wire Repairs The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. GMLAN Wiring Repairs GMLAN Wiring Repairs Special Tools J-38125 Terminal Repair Kit The GM Local Area Network (GMLAN) System requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working on GMLAN connectors and terminals. The tool kit J-38125 contains the following items in order to repair the GMLAN wiring: * DuraSeal splice sleeves * A wire stripping tool * J 38125-8 Crimping Tool * J 38125-5 Ultra Torch Special Tool The DuraSeal splice sleeves have the following 2 critical features: * A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. * A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J-38125 also serves as a generic terminal repair kit. The kit contains the following items: * A large sampling of common electrical terminals * The correct tools in order to attach the terminals to the wires * The correct tools in order to remove the terminals from the connectors GMLAN Repairs Note: When making a repair to any GMLAN network, the original wire length after the repair must be the same length as before the repair. If the network is a twisted pair, the twist must be maintained after the repair is completed. GMLAN has 2 types of networks, low speed and high speed. Low speed GMLAN has a single wire and works at slow speeds. High speed GMLAN has 2 wires in a twisted pair and works at higher speeds. For more information on GMLAN, refer to Data Link Communications Description and Operation ( See: Powertrain Management/Computers and Control Systems/Information Bus/Description and Operation). GMLAN Connector Terminal Repair Note: A service terminal can be used to replace damaged connector terminals for both high speed and low speed GMLAN systems. When making a connector terminal repair on a GMLAN high speed system with twisted pair wires, do not untwist the wires more than necessary to make the repair. The terminals in the GMLAN system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are available in the J-38125. If the individual terminals are damaged on any GMLAN connection, use the appropriate connector repair procedure in order to repair the terminal. Refer to Connector Repairs (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Connector Repairs/Connector Repairs) for the appropriate connector repair procedure. Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Page 5619 Window Motor - Driver (without AXG or LTZ) Page 7454 1. Install the center floor air duct. 2. Install the Instrument panel lower bracket. Refer to Instrument Panel Lower Bracket Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Lower Bracket Replacement). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 3. Install the center floor air duct screws and tighten to 1.5 Nm (13 lb in). 4. Install the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). Floor Rear Air Outlet Duct Replacement - Left Side Floor Rear Air Outlet Duct Replacement - Left Side Removal Procedure 1. Remove the console. Refer to Front Floor Console Replacement (See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Front Floor Console Replacement). 2. Remove the left front seat. Refer to Front Seat Replacement - Bucket (See: Body and Frame/Seats/Service and Repair/Removal and Replacement/Front Seat Replacement - Bucket). 3. Remove the left front carpet retainer. Refer to Front Side Door Opening Floor Carpet Retainer Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Removal and Replacement/Front Side Door Opening Floor Carpet Retainer Replacement). 4. Remove the left center pillar lower garnish molding. Refer to Center Pillar Lower Garnish Molding Replacement (See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Center Pillar Lower Garnish Molding Replacement). 5. Remove the floor carpet enough to access the left rear floor duct. Refer to Front Floor Panel Carpet Replacement (See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Removal and Replacement/Front Floor Panel Carpet Replacement). Page 8238 * Most of AFLs connectors have EPC on their connector body. Some of the smaller connectors will not have any markings on them. * In some cases Bosch will actually be printed on the connector. If Bosch does not appear on the connector, look for the Bosch logo. The Bosch logo is a circle with a blunted arrow inside. This logo can appear anywhere on the connector and is often very small. Page 2190 7. Reposition the radiator outlet hose clamp at the thermostat cover. 8. Remove the radiator outlet hose from the thermostat cover. 9. Remove the exhaust heat shield bolts (1). 10. Remove the exhaust heat shield. Page 343 Page 7451 2. Remove the left hand side window defogger duct screws. 3. Remove the left hand side window defogger duct. Installation Procedure 1. Install the left hand side window defogger duct. Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the left hand side window defogger duct screws and tighten to 2.5 Nm (22 lb in). 3. Install the I/P assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). Side Window Defogger Outlet Duct Replacement - Right Side Locations Air Flow Meter/Sensor: Locations Front of Vehicle/Engine Compartment Component Views Engine Compartment Components (LAT or HP7) 1 - Windshield Wiper Motor 2 - Electronic Brake Control Module (EBCM) 3 - Fuse Block Underhood 4 - Engine Control Module (ECM) 5 - Starter Generator Control Module (SGCM) 6 Battery Current Sensor 7 - Transmission Control Module (TCM) (ME7) 8 - Battery 9 - Brake Master Cylinder Pressure Sensor 10 - Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor 11 Brake Booster Vacuum Sensor 12 - Brake Fluid Level Switch Page 2986 Disclaimer Page 6021 2. Test a DC voltage range of 0.1-1000 V. 3. Test an AC voltage range of 0.1-1000 V. Amperage 1. Test a DC amperage range of 0.1µA-10 A. 2. Test an AC amperage range of 0.1µA-10 A. Resistance Test a resistance range of 0.1 ohm-40 Mohm and displays infinite for a value greater than 40 M ohm (O.L. (Over-load)) Frequency Test for a frequency range of 0.5 HZ-199 K HZ Diode Test 1. Apply at least 1 mA when performing the diode bias test 2. Display the break over voltage drop (0-3 V) of a forward biased diode 3. Display infinite (O.L. (Over-load)) when a diode is reverse biased Min-Max Readings 1. Can update at a 1 ms sample rate 2. Saves and displays minimum and maximum values Note: Circuits which include any solid state control modules, such as the powertrain control module (PCM), should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200 Digital Multimeter (DMM). The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present if the impedance is low enough, a DMM indicates how much voltage is present. In other words, if there is not enough current, the test lamp will not illuminate even though voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. Note: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: * Probe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors). * Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. * If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Using Connector Test Adapters Using Connector Test Adapters Caution: Do not insert test equipment probes (DMM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the EL-38125-580 GM Approved Terminal Release Tool Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the EL-38125-580 GM Approved Terminal Release Tool Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the EL-38125-580 GM Approved Terminal Release Tool Kit label on the inside of the EL-38125-580 GM Approved Terminal Release Tool Kit for the correct adapter along with the connector end view for terminal size. Page 5400 Camshaft Position (CMP) Sensor - Bank 2 Intake (LY7) Page 3120 Coolant Temperature Sensor/Switch (For Computer): Service and Repair Engine Coolant Temperature Sensor Replacement Removal Procedure Caution: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Drain the cooling system. Refer to Cooling System Draining and Filling (See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining and Filling). 2. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor (2). 3. Remove the ECT sensor (1) from the thermostat housing. Installation Procedure Page 7153 Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 11. Install the upper strut shaft nut and tighten to 70 Nm (52 lb ft). 12. Using the J 45400, remove the spring tension. 13. Remove the strut assembly from the J 45400. 14. Install the strut assembly. Refer to Strut Assembly Replacement (See: Suspension Strut / Shock Absorber/Service and Repair/Front Suspension Strut/Strut Assembly Replacement). Electrical - Various Electrical Systems Malfunctions Body Control Module: All Technical Service Bulletins Electrical - Various Electrical Systems Malfunctions TECHNICAL Bulletin No.: 08-05-22-009C Date: September 30, 2010 Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined) Models: 2004-2008 Chevrolet Malibu, Malibu Maxx 2008 Chevrolet Malibu Classic 2008-2011 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2009 Saturn AURA Supercede: This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes). Condition Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set. Cause The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59). Correction DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion. 1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM). 2. Locate the C2 or X2 connector on the BCM. 3. Unlatch the connector and disconnect the connector from the BCM. 4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion. 5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant. 6. Reinstall the right side front floor console side trim panel. 7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed. - If they are equal, the brake lamps should be operating correctly and no further steps are necessary. - If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair. 8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics. Warranty Information For vehicles repaired under warranty, use the table. Page 848 1 - Ignition Coil 1 2 - Ignition Coil 3 3 - Ignition Coil 5 4 - Heated Oxygen Sensor (HO2S) - Bank 1 Sensor 1 5 - Knock Sensor (KS) 1 6 - Starter Solenoid (part of Starter Motor) 7 - Starter Motor 8 Knock Sensor (KS) 2 9 - Engine Oil Pressure (EOP) Switch 10 - Crankshaft Position (CKP) Sensor Lower Front and Rear of the Engine Components - Oxygen Sensors (LY7) Page 4354 During your call with GM TAC on a current case, you may be advised to send a copy of the Tech 2(R) or VDR Snapshot Data to the TAC e-mail box. U.S. Dealers - send to e-mail box [email protected] Canadian Dealers - send to e-mail box [email protected] Please complete the following: - Be sure to review the procedures listed above for uploading and sending a Snapshot via TIS2WEB. - If you are using a VDR to capture Snapshot Data, information can be accessed in the Techlink Website in the articles (December 2002, December 2003, July 2004 and January 2006). - Please be sure to identify the snapshot by placing the TAC Case Number, the last eight digits of the VIN and the type of data (i.e. engine or transmission) in the subject line of your e-mail. The email Subject Line MUST contain the TAC case number and last 8 digits of the VIN or their email can not be processed and will be deleted. Please send only REQUESTED Snapshot Data to the TAC e-mail box. Disclaimer Page 9108 Page 6545 X900 Decklid Jumper Harness to Decklid Harness Page 9123 Page 1782 4. Remove the connecting rod nuts and the connecting rod cap. Discard the bolts and nuts. 5. Remove the connecting rod and the piston out of the top of the engine block using the EN-43966-1 - guides. 6. Clean the cylinder bores with hot water and detergent or with a light honing. 7. Swab the bores with the engine oil and a clean, dry cloth. Installation Procedure 1. Coat the following parts with engine oil: * The piston * The piston rings * The cylinder bore * The bearing surfaces Page 10355 If only bulbs are replaced, use labor operation N0440 or N0441. Disclaimer Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt: Testing and Inspection Drive Belt Chirping, Squeal, and Whine Diagnosis Drive Belt Chirping, Squeal, and Whine Diagnosis Diagnostic Aids * A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution. * If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. * A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise. * The drive belts will not cause a whine noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 15. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 16. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 17. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. 19. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Page 6010 Checking Aftermarket Accessories Checking Aftermarket Accessories Warning: Refer to SIR Warning (See: Restraint Systems/Service Precautions/SIR Warning). Caution: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit. Do not connect aftermarket accessories into the following circuits: * SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. * OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: * Power feeds connected to points other than the battery * Antenna location * Transceiver wiring located too close to vehicle electronic modules or wiring * Poor shielding or poor connectors on antenna feed line * Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Circuit Testing Circuit Testing The Circuit Testing section contains the following diagnostic testing information. Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction. * Using Connector Test Adapters (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Using Connector Test Adapters) * Probing Electrical Connectors (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Probing Electrical Connectors) * Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Page 10105 crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. 6. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Heated Oxygen Sensor Wiring Repairs Heated Oxygen Sensor Wiring Repairs Special Tools J-38125 Terminal Repair Kit Caution: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. Page 7583 A/C Coupler O-ring: Service and Repair Air Conditioning O-Ring Seal Replacement Air Conditioning O-Ring Seal Replacement Removal Procedure 1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure. 2. Remove the O-ring seal from the A/C refrigerant component. 3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. Important: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seal. Installation Procedure 1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil. Important: DO NOT reuse O-ring seals. 5. Carefully slide the new O-ring seal onto the A/C refrigerant component. 6. The O-ring seal must be fully seated. 7. Assemble the A/C components. Refer to the appropriate repair procedure. Page 7686 For vehicles repaired under warranty, use the table. Disclaimer Locations Antenna Control Module: Locations Luggage Compartment/Rear of Vehicle Component Views Rear Window Shelf Components 1 - Cellular (UE1) and Digital Radio Antenna (U2K) 2 - Radio Antenna Module 3 - Remote Start Antenna (AP3) 4 - Speaker - Right Rear 5 - Accessory AC/DC Power Control Module (KV1) 6 Audio Amplifier (UQ3) 7 - Rear Compartment Courtesy Lamp 8 - Remote Control Door Lock Receiver (RCDLR) 9 - Digital Radio Receiver (U2K) 10 - Speaker - Left Rear Page 4192 5. Slide the two halves (1, 2) of the range select cable together until all free play is removed. 6. Depress the adjuster clip (1) locking the adjuster clip completely. 7. Pull both halves of the range select cable in opposite directions to verify the cable adjuster is secured. 8. Check the transmission range select lever in all gear selections for proper operation. Page 6851 * A flush rotor flange cuff (4) Note: If you are reusing the existing sensor, make an alignment mark (3) on the rotor flange cuff before removing the sensor. Failure to do so will cause misalignment of the old sensor. Replace a misaligned sensor with a new sensor. 8. Make an alignment mark on the flush rotor flange cuff. 9. Remove the connector from the sensor. 10. Remove the sensor from the adapter and bearing assembly. 11. To install the sensor, proceed to step 4 in the installation procedure. 12. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note the location of the pin hole. 13. Remove the connector from the sensor. 14. Remove the sensor from the adapter and bearing assembly. 15. To install the sensor, proceed to step 8 in the installation procedure. 16. From the technicians point of view, the FRONT of the sensor will have: * A raised rotor flange cuff (3) * An alignment mark (2) on the rotor flange cuff for installation * A pin hole (1) for the centering pin-Note location of the pin hole. * A sensor clip in FRONT of the sensor 17. Remove the connector from the sensor. 18. Remove the sensor clip from the sensor. 19. Remove the sensor from the adapter and bearing assembly. 20. To install the sensor, proceed to step 12 in the installation procedure. Page 10556 17 - Data Link Connector (DLC) 18 - Inflatable Restraint Steering Wheel Module 19 - Fog Lamp Switch (T96) 20 - I/P Dimmer Switch 21 - Steering Wheel Control Switch - Left Service and Repair Spoiler: Service and Repair Rear Spoiler Replacement Page 4340 Note: The clutch fluid passage seal is not reusable. 1. Install a NEW 1-2-3-4 clutch fluid passage seal (3). Note: Ensure the control solenoid valve spring is attached to the lower control valve body assembly. Note: Align the manual valve (2) to the detent lever assembly while installing the lower control valve body assembly. 2. Install the control valve body assembly (1). Note: Ensure proper alignment of the detent assembly to the detent lever assembly with position switch while tightening the bolt. The detent assembly can move and hit the valve body assembly that could cause improper engagement with the detent lever assembly. 3. Install the manual shaft detent assembly (2). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). Page 10198 1. Install the park brake warning lamp switch (2) to the park brake pedal assembly (1). Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution). 2. Install the park brake warning lamp switch screw (3) and tighten to 2 Nm (18 lb in). 3. Connect the electrical connector to the park brake warning lamp switch. 4. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Replacement - Left Side (See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Insulator Replacement - Left Side). 5. Check the operation of the park brake warning lamp switch. Page 9187 9. The illustration shows a cutaway view of the connector to aid the technician in releasing the terminal retainer. 10. See the release tool cross reference in the Reference Guide of the J-38125 Terminal Repair Kit to ensure that the correct release tool is used. Terminal Repair Procedure Refer to the terminal crimping procedure in the Reference Guide of the J-38125 Terminal Repair Kit. Terminal Replacement Procedure After the terminal is crimped to the wire, perform the following procedure in order to replace the terminal. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Ensure that the terminal is locked in place by gently pulling on the wire. 3. To assemble the connector, reverse the connector disassembly procedure. Terminal Position Assurance Locks Terminal Position Assurance Locks The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. If the TPA is removed, be sure to reinstall it before reconnecting the connector. Circuit Protection - Circuit Breakers Circuit Protection - Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker - This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker - This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close Page 3807 25 - Torque Converter and Support and A/Trans Fluid Pump Housing Assembly 26 - Torque Converter and Differential Housing Bolt 27 - Torque Converter Assembly 28 - Dust Cover Push Pin - Model Dependent 29 - Dust Cover Bolt - Model Dependent 30 - Dust Cover - Model Dependent 31 - Front Differential Carrier Assembly 32 - Input Shaft Thrust Bearing Assembly 33 - A/Trans Case Cover Gasket 34 - A/Trans Case Cover Assembly 35 - A/Trans Case Cover Assembly Bolt Catalytic Converter Replacement Catalytic Converter: Service and Repair Catalytic Converter Replacement Catalytic Converter Replacement Removal Procedure 1. Remove the heated oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 2 (See: Computers and Control Systems/Oxygen Sensor/Service and Repair/Heated Oxygen Sensor Replacement - Sensor 2). 2. Remove the catalytic converter to exhaust manifold nuts (1). 3. Remove the catalytic converter to muffler nuts (1). 4. Separate the exhaust pipe from the catalytic converter studs. 5. Position and support the exhaust pipe out of the way. 6. Remove the catalytic converter (2) and gasket. Page 4410 Wheel Bearing: Service and Repair Rear Suspension Rear Wheel Bearing and Hub Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair ). 3. Remove the brake rotor. Refer to Rear Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Rear Brake Rotor Replacement). 4. Disconnect the electrical connector from the wheel speed sensor. 5. Remove the 4 wheel bearing/hub assembly nuts. 6. Remove the wheel bearing/hub assembly from the knuckle. Installation Procedure Page 6060 7. View of the male half of the connector with female terminals. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. Repair Procedure Use the appropriate terminal and follow the instructions in the J-38125. Location of the terminal in the repair tray and the proper crimp tool can be found in the appropriate connector end view. Repairing Connector Terminals Repairing Connector Terminals Special Tools J-38125 Terminal Repair Kit Use the following repair procedures in order to repair the following: * Push to Seat terminals * Pull to Seat terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal. 2. Apply the correct cable seal per gauge size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For sealed terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal. Sumitomo Connectors Page 1842 8. Install the camshaft roller followers. 9. Install the camshaft. Refer to Intake Camshaft and Valve Lifter Replacement (See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Intake Camshaft and Valve Lifter Replacement) or Exhaust Camshaft and Valve Lifter Replacement (See: Camshaft, Lifters and Push Rods/Camshaft/Service and Repair/Exhaust Camshaft and Valve Lifter Replacement). 10. If used, remove the EN-43653 - holding tool. 11. If removed, install the starter. Refer to Starter Replacement (See: Starting and Charging/Starting System/Starter Motor/Service and Repair). Page 1450 Fuse Block - Underhood X2 Page 9943 Note: The TPA cannot be removed from the connector while there are terminals present in the connector body. 3. Use a small flat-blade tool to very carefully raise the TPA on both sides of the connector. 4. View of the TPA when removed from the connector body. Page 8231 Using Fused Jumper Wires Using Fused Jumper Wires Special Tools J 36169-A Fused Jumper Wire Note: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. AFL/EPC Connectors AFL/EPC Connectors Special Tools J-38125 Terminal Repair Kit Removal Procedure Follow the steps below in order to remove terminals from the connector. 1. For connectors with a bolt in the dress cover, turn the bolt counterclockwise to remove the connector from the component. Page 6699 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Locations Battery Control Module: Locations Luggage Compartment/Rear of Vehicle Component Views Lower Front of the Rear Compartment Components (HP7) 1 - Generator Battery 1 2 - Generator Battery Temperature Sensor 1A 3 - Generator Battery Temperature Sensor 1B 4 - Generator Battery 2 5 - Generator Battery Temperature Sensor 2A 6 Generator Battery Temperature Sensor 2B 7 - Generator Battery 3 8 - Generator Battery Temperature Sensor 3A 9 - Generator Battery Temperature Sensor 3B 10 - Generator Battery Vent Fan 11 - Battery Current Sensor 12 - Main Contactor Relay 13 - Battery Disconnect Switch 14 Generator Battery Disconnect Control Module Page 10041 Page 5998 Page 7332 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Page 5227 3. Using terminal tool J-38125-11A or equivalent, release the wire dress cover locking tabs. 4. Pivot connector wire dress cover while removing from the connector body. Page 2896 same gauge size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal splice sleeves and splice crimping tool from the J-38125 and then encapsulate the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. Note: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip keeping all of the wire strands intact. 1. Open the harness by removing any tape. 2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage. 3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 4. Strip the insulation: * When adding a length of wire to the existing harness, use the same size wire as the original wire. * Perform one of the following items in order to find the correct wire size: - Find the wire on the schematic and convert the metric size to the equivalent American wire gauge (AWG) size. - Use an AWG wire gauge. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. * Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. * Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. * If the wire is damaged, repeat this procedure after removing the damaged section. 5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure. 6. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests. 7. Use the Splice Crimp Tool from the J-38125 in order to position the DuraSeal splice sleeve in the proper color nest of the Splice Crimp Tool. The crimp tool has three nests, (1) is for the salmon and green splice sleeve, (2) is for the blue splice sleeve, and (3) is for the yellow splice sleeve. Page 6334 Horn Switch Page 7404 3. Reconnect the wheel speed senor electrical connector, if needed. 4. Install the wheel speed sensor electrical connector on the retaining bracket, if needed. 5. Install the brake rotor. Refer to Front Brake Rotor Replacement (See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Front Brake Rotor Replacement). 6. Install the wheel drive shaft retaining nut and washer. Refer to Wheel Drive Shaft Replacement (See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Service and Repair/Wheel Drive Shaft Replacement). 7. Remove the support and lower the vehicle. Page 2904 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Start in the middle and gradually move the heat barrel to the open ends of the tubing: * The tubing will shrink completely as the heat is moved along the insulation. * A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes Splicing Inline Harness Diodes Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. * If the harness is taped, remove the tape. * To avoid wiring insulation damage, use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness. * If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. Note: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. Note: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable Splicing Twisted or Shielded Cable Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the MYLAR tape. Page 2360 Engine Control Module (ECM) X2 (LY7) Page 5600 Tail/Stop and Turn Signal Lamp - Left (LTZ) Page 675 Dimmer Switch: Diagrams Component Connector End Views I/P Dimmer Switch Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder Replacement Page 6776 Courtesy Transportation - For US and Canada The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Warranty Transaction Information 1. Submit a transaction using the table below. * The amount identified in the Net Item column should represent the actual cost of the woven polyester electrical tape, required for the repair, if used, not to exceed $0.50 USD, $0.51 CAD. Customer Notification - For US and Canada General Motors will notify customers of this program on their vehicle (see copy of customer letter included with this bulletin). Customer Notification - For Export Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter. Dealer Program Responsibility All unsold new vehicles in dealers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Owner Letter Owner Letter Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a customer satisfaction program that affects your 2008 model year Buick Enclave, GMC Acadia, or Saturn OUTLOOK vehicles, or your 2010 model year Chevrolet Malibu or Pontiac G6 vehicle. Page 5945 6. On the body harness, position two FEMALE terminals onto the wires. Caution must be used not to position the wire too far forward as it may interfere with the mating portion of the terminal. Crimp the terminals on to the bare wire using the J38125-7 crimp tool, jaw E (1). Repeat the procedure using two MALE terminals on the seat airbag harness. 7. Position the wire seal to the terminal and crimp the seal and insulation using the J-38125-6 crimp tool, jaw 1 (1). The completed terminal and seal should appear as shown above (body harness connector shown). Note Avoid getting solder on the terminal end or overheating the terminal. Warning DO NOT use soldering equipment that is battery or electric powered. These types of soldering irons can induce voltage into the circuit, which may cause inflator module deployment and/or damage to electrical components. Use only the EL-28125-5 Ultra Torch or another butane fueled soldering iron when working on SIR circuits. 8. Solder all four terminals at the wire crimp. 9. Slide the two body harness terminals through the opening of the orange connector position assurance (CPA) (1). Note Page 2624 Intake Air Temperature Sensor: Diagrams Component Connector End Views Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LAT or LE5 or LE9) Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor (LY7) Page 9479 Page 6017 Testing for Electrical Intermittents Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. * Testing for Short to Ground (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Short to Ground) * Testing for Continuity (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for Continuity) * Testing for a Short to Voltage (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Testing for a Short to Voltage) If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. Note: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Troubleshooting with a Digital Multimeter) for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Note: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions (See: Testing and Inspection/Component Tests and General Diagnostics/General Electrical Diagnostic Procedures/Circuit Testing/Inducing Intermittent Fault Conditions). 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. * If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. * If the variation between the recorded MIN and MAX voltage values is less than 1 V, an intermittent open or high resistance condition does not exist. Testing for Intermittent Conditions and Poor Connections Testing for Intermittent Conditions and Poor Connections Special Tools * J 35616 GM-Approved Terminal Test Kit * J-38125 Terminal Repair Kit When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition. Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: * Wiring broken inside the insulation * Poor connection between the male and female terminal at a connector * Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc. * Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little Page 9153 * JAE connector have JAE in small letters on their connectors. * JST connectors have JST in small letters on their connectors, similar to that above. The location of the logo will vary with the connector size and style. Page 7440 Air Duct: Service and Repair Instrument Panel Outer Air Outlet Upper Duct Replacement - Right Side Instrument Panel Outer Air Outlet Upper Duct Replacement - Right Side Removal Procedure 1. Remove the instrument panel (I/P) assembly. Refer to Instrument Panel Assembly Replacement (See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Assembly Replacement). 2. Remove the right hand side window defogger duct screws. 3. Remove the right hand side window defogger duct. 4. Disconnect the wire harness clip at the right air outlet duct. 5. Remove the right air outlet duct screws. 6. Remove the right air outlet duct. Page 5509 I/P Dimmer Switch Page 7845 Dear General Motors Customer: This notice is sent to inform you that General Motors is conducting a Customer Satisfaction Program that affects your 2010 model year Chevrolet Malibu or Pontiac G6. We have learned that your 2010 model year Chevrolet Malibu or Pontiac G6 may have a condition in which wear could lead to corrosion in the connector terminal pins at the connection between the body main wiring harness and the front driver and passenger side impact airbag. Over time, the wear may result in a resistance value that sets a SERVICE AIR BAG system warning message in the Driver Information Center (DIC). The seat side impact air bag would continue to be fully functional. Over time, and if the SERVICE AIR BAG system DIC warning message is ignored, the resistance could increase to a level in which the seat side impact air bag may not deploy when commanded in a side impact crash. Your Malibu or G6 may have been serviced previously to reroute and secure both front seat-mounted side impact airbag wire harnesses. However, there have been reports of the SERVICE AIR BAG message illuminating in the Driver Information Center (DIC) on vehicles that had the wire harnesses rerouted and secured, but did not have new connectors installed. Our records indicate that your vehicle may not have had the new connectors installed. What We Will Do: Since your vehicle may not have had new connectors installed, your GM dealer will inspect your vehicle to determine if new connectors have been installed, and will install two new connectors, if required. This service will be performed for you at no charge. What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. Courtesy Transportation If your vehicle is within the New Vehicle Limited Warranty, your dealer may provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner Manual and your dealer for details on Courtesy Transportation. We sincerely regret any inconvenience or concern that this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your GM vehicle provides you many miles of enjoyable driving. Jim Moloney General Director, Customer and Relationship Services 11034 Page 3553 Knock Sensor: Service and Repair Knock Sensor Replacement Removal Procedure 1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (See: Starting and Charging/Battery/Battery Cable/Negative/Service and Repair/Battery Negative Cable Disconnection and Connection). 2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance/Vehicle Lifting/Service and Repair). 3. Disconnect the engine wiring harness electrical connector (1) from the knock sensor pigtail electrical connector (6). 4. Remove the knock sensor electrical connector pigtail (6) clip from the oil level indicator tube bracket. 5. Remove the knock sensor bolt. 6. Remove the knock sensor. Installation Procedure Page 7672 9. Remove the suction hose from the dash clip. 10. Remove the line clip from the dash. 11. Remove the refrigerant pressure sensor wire harness connector. 12. Remove the liquid line bracket bolt. Page 5786 Relay Box: Locations Fuse Block - Rear Electrical Center Identification Views Fuse Block - Rear Label Front Seat Cushion Cover and Pad Replacement Seat Cushion: Service and Repair Front Seat Cushion Cover and Pad Replacement Front Seat Cushion Cover and Pad Replacement